Posts Tagged ‘Lighting’

The Purple Light ‘UV’ Cure Cube

The Cure Cube is used for curing SLA 3D Prints created on the Form Labs 1+ printer. Exposing SLA prints to 405nm "UV" light increases strength and creates a harder surface for final finishing.

The Cure Cube is used for curing SLA 3D Prints created on the Form Labs 1+ printer. Exposing SLA prints to 405nm “UV” light increases strength and creates a harder surface for final finishing.

While not particularly visible to everyone in the SSL universe, over the past few years one area of interest in LED product development for me has been in use of 405nm LED light sources to cure various plastics materials. The advantages are lower power requirements and reduced overall heat in the cure zone over conventional fluorescent or HID light sources. This has been of particular interest in curing fiberglass resins manufactured by Sunrez. The typical demand is for between 200 and 1,000 µW/CM² at 400-405nm wavelength. The use of LEDs allows us to generate exactly that without the waste of visible light, and longer wavelength power the resins are not reacting to. In one project, we were able to replace a 1,500W HID light source with a 120W LED light system that produced faster cure times with less than 10% of the total power, and virtually no heat added to the heat generated by the resin’s exothermic reaction to the curing initiator. Since then, we’ve built 405nm light cure fixtures ranging from 1,200W to 25W.

In this case, I needed to cure 3D prints we generate on a Form Labs 1+ 3D SLA printer, and do so in an office environment without exposing other materials and occupants to UVA light output. The material used in the print process is acrylic based, with chemistry that is photo-reactive to 405nm. The actual prints are made using a UV laser source. When the part is removed from the printer it is washed in alcohol (91% IPA), rested for a few hours to dry the alcohol off, then placed in this cure cube for an hour or more, depending on the thickness of the final component. The end result is a hard first surface for finish sanding or painting, if necessary, and a more rigid part as a whole (less flexible).

The cube is simple, with vent reliefs top and bottom to encourage ariflow. The flush switch on the top cover was created using 3D printing processes for the slider and body, as well as top and bottom cover.

The cube is simple, with vent reliefs top and bottom to encourage ariflow. The flush switch on the top cover was created using 3D printing processes for the slider and body, as well as top and bottom cover.

The cube utilizes a simple aluminum housing, with FDM 3D printed top and bottom covers. The top cover houses a single Recom 500mA driver, slide switch and wiring terminal block on a Tasca LED driver circuit board.

5mm 450nm LEDs with a FWHM distribution of 60º, 25 per side and top (125 total), operating at 20mA each, mounted to custom circuit boards sourced at Express PCB. Each board connects the LEDs in parallel, while the boards are connected in series, resulting in a 500mA, 15.4V circuit, totaling 7.7W. The boards and internal exposed surfaces inside the box were then covered with White Optics 98 matte material to increase total light energy and diffuse The light energy at 405nm is roughly 600 µW/CM².

The bottom surface includes a glass plate where the product sits in order to make any possible stickiness of a part from adhering to the White Optic material below.

The interior of the cube is covered with White Optics 98 material for optimizing light energy re-cycling.

The interior of the cube is covered with White Optics 98 material for optimizing light energy re-cycling.

The housing was powder coated matte black polyester to make clean up easy and the box look nice. The overall interior dimensions of the box are 1″ larger than the total build volume capacity of the printer itself (5 x 5 x 6.5), as any over-sizing is unnecessary. This produces an optimal match between the location of the LED sources and any part the printer can produce.

The Cube is powered by a remote plug mounted 24VDC power converter.

The operation of the box is simple enough. The box is lifted up, the part is set on the base, the box is set over the part, and the light is turned on by sliding the switch to the on position.

Simple and compact is the order of desktop manufacturing, and this fits that model perfectly.

A look into the box lighted up and ready to accept parts.

A look into the box lighted up and ready to accept parts.

Testing so far has shown the cube can cure raw resin from liquid to fully hardened in less than an hour, and strengthens prints in that time or less. The heat generated from this arrangement is so small, there is no chance of any part being warped or affected by the process, other than the desired results of becoming stronger.

For parts to be left unfinished, that are desired to be used over extended periods, we coat the finished parts in either acrylic or polyurethane UV inhibiting clear coat, gloss or matte. This stops ambient room light or daylight exposure from making the parts brittle over time. I am building a second copy of this cube for completing extended testing of samples of the materials we are using to verify clear coat effectiveness, behavior of the print material over long exposure periods, and the behavior of these low cost LEDs over time. A commercial version of this cube could be made using more robust LEDs, but the costs would be significantly higher as well. In the current configuration, the LEDs only cost $0.60 each, so should they last a couple of years in use, replacement of the populated boards is a simple task, while the cost of higher power LEDs would have increased the cost of the entire end-product by as much as three times.

There is also an additional version of this same approach in using Red/Blue light sources for use in plant seedling starts. We’ve found tests with common rye and barley grasses, the time from germination to hearty growth ready for planting is accelerated significantly. Using an enclosure like this allows the plants to be exposed to intense light for extended periods of time (18 hours or more) without polluting the surrounding environment with the ugly light, just as the enclosed cube protects room occupants from exposure the the UVA light. In either case, the cube can be used in any room environment comfortably and safely.

So this gets us off the ground and is D1 of 52 in the series. As I’ve noted at the start, this is an exercise in making progress, and putting SSL to work. This is not a particularly exciting product in and of itself, but it is one that will be used regularly, which more than makes up for its lack of marketing sizzle for the masses – at least in my book.

 

My first LED fixture - 2004-2006

My first LED fixture – 2004-2006

This is my last bit of housecleaning from blogs being shut down, for the archives. KLW

This fixture is my very first LED light. It started life to be a halogen fixture in 2004, that sat on a workbench waiting completion. The first head got so hot from the 50W 12V light source, it was dangerous, so it sat as I decided what to do with it.

In 2005, as LEDs became viable for lighting, I pondered using them to replace the halogen source, but they delivered so little light, the end product was useless as a desk lamp, so it sat some more. One idea was to insert a Lamina BL3000 LED into the head, but the driver was huge, the light output too little, and the heat still an issue.

Then, in early 2006, while at Visa Lighting, Don Brandt (an engineer working with me at Visa, formerly from Emteq, now working at Cree I believe) were talking through ways of applying the latest mid-power LEDs using a simple PCB. We decided to give it a shot and built a board populated by a vendor with 8 Nichia LEDs. The inspiration struck to power these LEDs with two Xitanium drivers, which at the time were un-potted prototypes, so cutting them out of their housing to be installed in clear tubes to show their interiors off was easy enough. Two push-button switches activated the drivers for a high-low effect, and a heat sink was made up of a machined aluminum block installed in the head where the original halogen lamp and reflector once lived. More details and images of this can be found on the Lumenique archives for the Ratchet fixture.

The fixture itself is made of welded steel structure with a brass head and fiberglass tension springs. The head can be raised an lowered with a ratcheting action, staying level at any height. In the end, I left this fixture with the owner of the Oldenburg Group (owner of Visa Lighting) as a parting gift as I moved on to focus on Lumenique and SSL exclusively.

There are many subjects in lighting, specifically in the universe of solid-state lighting, that need to be actively discussed and openly debated. Issues such as qualitative issues (color, color accuracy, glare, brightness, illuminance levels, etc..) over quantitative (lumens per watt), or the discussion of blue light content, or scotopic v. photopic, or supplier issues, or even the problems of being a small fish in a pond filled with big bloated corporate fish and a governmental agency who believes itself now a lighting expert… These all require active dialog to be resolved and grow understanding.  Too many times, the discussion of important topics are held in little rooms, hidden from view, with conclusions drawn, recommendations and regulations written – to be handed down like tablets from the mount, for us all to simply step in line and accept as fact. We have far too many instances of white paper writing scientists issuing their narrowly focused findings through their myopic peer groups, to be used as swords and weapons against the unwashed and unknowing masses. I find the creeping movement of lighting away from its roots as a human experience enhancing art-form into the hands of marketing zealots, narrow minded PhD’s working in their corporate labs, and federal or state agencies with agendas to follow outside our need to know… well, disheartening and disgusting. (more…)

In my previous entries regarding the Cree LR6, I’ve noted the good and bad sides of the product in some detail. I’ve noted my dissatisfaction with the brightness of the diffuser, which has caused me to first apply plastic trim rings to add a little cutoff, then later, to simply not turn them on. Dimming performance over the years has been disappointing as well. No dimmer I have found has dimmed them satisfactorily, most cause them to flicker. The latest from Lutron, designed specifically for LED/CFL sources, did not fix the issues, so I simply gave up. Rather than remove these expensive retrofits ($65.00+ each), I chose to do what many of us do when caught in a  quandary – stopped using them at all. Estimating these were not used more than an average of 1 hour a day for the last 4 years, total operating time is less than 1,500 hours. I’ll give them 2,000hrs, assuming that when they were first put in place, I used them more than I did as we grew tired of their glare and flickering under dimmer control. (more…)

Like the previous reviews of light meters, I am restricting this review to affordable temperature meters I have direct experience with in actual project work. Anyone who works with or applied LED technology should consider investing in some form of reliable temperature meter to test results of either products in development, or product performance in the field. The Achille’s Heel of solid-state technology is its susceptibility to failure and degradation from operating at high temperatures. This extends beyond the LED into the driver and power supply components, which are often placed under stress from fixture packaging or location near heat sources. The first issue that a manufacturer will raise when facing a field failure, will be the temperature the fixtures were operated in, either caused by the product design, or the physical application, heat kills LED products. That said, just like photometric test equipment, laboratories and large engineering departments will spend many thousands of dollars on test gear, and calibration services. That’s great if that is the focus of your business. For the rest of us, especially those in small business, the costs of test equipment must be weighed against the myriad of other tools and expenses. So, the question becomes, can one keep the costs low and still get reliable results. The following is an attempt to provide some insight into this, and show solutions I have found to be reliable after several years of using various products with varying degrees of satisfaction. (more…)

For anyone interested in saying hello in person, to knock ideas around, or just tell me what you think of things, meeting up at a conference is ideal. Since I try to bring original content to each venue, the time it takes to put a presentation together is enough that I usually limit the number of presentations to 3-5 a year. This year is about over, but I do have 3 more to go on the schedule, for anyone interested. (more…)

After reviewing a range of different metering choices in actual use, I compiled a summary of findings, as well as my own personal subjective ratings of features and overall utility as a lighting professional. This chart is the collection of all findings in a simple comparison table for those who find this useful (like me): (more…)