LED Lighting System

This is version 2 of my 3D printable LED lighting system, which is designed to be easy to wire and install. Given the appropriate constant current voltage regulator, lights can be linked in series to obtain the desired system. This is an excellent starter project for those just getting into 3D printing and electronics.

Details

• LED housing can host 3.6 cm X 3.6 cm X 2.0 cm heat sink, which is suitable for 5 W LEDs; clamping plate is secured using two 12 mm M3 bolts
• LED chips and heat sinks can be sourced from Amazon, LedSupply, etc.
  Note: heat sink must be sufficiently sized for natural convective heat transfer. Can use 'Celsia' heat sink sizing calculator (https://celsiainc.com/resources/calculators/heat-sink-size-calculator/) with Rv = 150 to obtain estimate of required heat sink.
• Each housing hosts standard 20 mm lens (source: Amazon etc.)
• The terminal blocks used are WAGO 2604-3102 (source: Galco, Newark, etc.); they are lever-secure type for easy wiring.
• Switch type is XL601 (source: Amazon etc.)
• Optional magnets have 2.75 mm thickness and 10 mm diameter (source: Amazon); they are used for securing the housings/switches to the undersides of metal surfaces (e.g. office desk overhang)
• Wire used is two-conductor 20 AWG (source: Amazon etc.)
• Since temperatures reach over 60C, ABS or ASA filament should be used

0.15

100%

ABS or ASA filament can be used, but ASA is preferred since it's easier to print. Print the light housings at 100% infill so light doesn't shine through it. Add a brim for each print (even if you have an enclosure), since it will fail otherwise.