From 00770d3a3e998f6d3369db7b48fbc9d1f30093dc Mon Sep 17 00:00:00 2001
From: "Jan \"Yenya\" Kasprzak" <kas@fi.muni.cz>
Date: Mon, 11 May 2015 12:55:25 +0200
Subject: [PATCH] diffuser - comments inside, more adjustable parameters

---
 diffuser-adjustable.scad | 69 ++++++++++++++++++++++++++++++++++++++++
 diffuser-zsj-t29.scad    | 41 ------------------------
 2 files changed, 69 insertions(+), 41 deletions(-)
 create mode 100644 diffuser-adjustable.scad
 delete mode 100644 diffuser-zsj-t29.scad

diff --git a/diffuser-adjustable.scad b/diffuser-adjustable.scad
new file mode 100644
index 0000000..8c47adf
--- /dev/null
+++ b/diffuser-adjustable.scad
@@ -0,0 +1,69 @@
+// A simple adjustable diffuser for the LED flashlights.
+//
+// Designed by Jan "Yenya" Kasprzak <kas at yenya.net>.
+// Distributable under the terms of the Artistic License.
+//
+// Tested with ZHISHUNJIA ZSJ-T29 LED flashlight (dx.com SKU #317226).
+// NOTE: I can't really recommend this particular flashlight, it is
+// well below the specs (600/300/150 mA instead of stated 2.4 A).
+//
+// For any other flashlight, adjust the parameters below:
+
+// the true _diameter_ of the flashlight + some space around
+ring_d = 34.3 + 1.0;
+
+// the diaphragm thickness, set so that it is printed with two print layers
+diaphragm = 0.5;
+
+// outer wall thickness - preferably the integer multiple
+// of the print trace width
+wall = 1.5;
+
+// height of the center of clip beams + some space below + diaphragm thickness
+clip_h = 7.3 + 0.5 + diaphragm;
+
+// the clips protrude this much to the inner cylindrical hole
+// the bigger value means more stiff fit
+clip_w = 1.2;
+
+clip_angle = 120; // at least 90 degrees; bigger is easier to put on and off,
+	// smaller is more stiff, but harder to remove
+
+n_clips = 3; // number of clips; odd numbers prefered
+
+// the height of the clip is computed so that there is wall/2-wide flat
+// on top of the clip
+clip_top = clip_h + (clip_w+wall/2)*tan(clip_angle/2);
+
+// the overall height:
+// ring_h = clip_top; // cylindrical shape without the clips protruding on the top
+ring_h = clip_h + wall; // clips protruding on the top
+
+infty = 100;
+eps = 0.01;
+
+module diffuser() {
+	difference() {
+		// outer cylinder
+		cylinder(r = ring_d/2 + wall, h = ring_h);
+		// inner cylinder hole + diaphragm
+		translate([0, 0, diaphragm])
+			cylinder(r = ring_d/2, h = ring_h);
+		translate([0, 0, ring_h + eps - wall])
+			cylinder(r1 = ring_d/2, r2 = ring_d/2 + wall/2, h = wall);
+	}
+	// clip beams
+	for (angle = [0:360/n_clips:360-eps]) intersection() {
+		rotate([0,0,angle])
+			translate([ring_d/2-clip_w, -infty/2, clip_h]) {
+				rotate([0, 90-clip_angle/2, 0])
+					cube(infty);
+				rotate([0, clip_angle/2, 0])
+					cube(infty);
+			}
+		cylinder(r = ring_d/2 + wall, h = clip_top);
+	}
+}
+
+diffuser();
+
diff --git a/diffuser-zsj-t29.scad b/diffuser-zsj-t29.scad
deleted file mode 100644
index 27bdcb8..0000000
--- a/diffuser-zsj-t29.scad
+++ /dev/null
@@ -1,41 +0,0 @@
-// Diffuser for ZHISHUNJIA ZSJ-T29 LED flashlight (dx.com SKU #317226).
-infty = 100;
-eps = 0.01;
-
-diaphragm = 0.5; // diaphragm thickness
-wall = 1.5;
-
-ring_h = 12; // the height of the body
-ring_d = 34.3 + 1.0; // the lens ring diameter + tolerance
-
-clip_h = 7.3 + 1.0; // height of the clip above the diaphragm
-clip_dist = 1.5;
-clip_size = 1.2;
-
-
-module diffuser() {
-	difference() {
-		cylinder(r = ring_d/2 + wall, h = ring_h);
-		translate([0, 0, diaphragm])
-			cylinder(r = ring_d/2, h = ring_h);
-		for (angle = [0:120:360]) rotate([0,0,60+angle]) {
-			translate([0, 0, 20+clip_h])
-			rotate([0, 90, 0])
-				cylinder(r=20, h=infty);
-		}
-	}
-	for (angle = [0:120:360]) rotate([0,0,angle]) {
-	 	intersection() {
-			hull() {
-				translate([ring_d/2-clip_dist, -infty/2, clip_h])
-					cube([infty, infty, clip_size]);
-				translate([ring_d/2+wall/2, -eps/2, ring_h+wall])
-					cube([eps, eps, eps]);
-			}
-			cylinder(r = ring_d/2 + wall/2, h = ring_h);
-		}
-	}
-}
-
-diffuser();
-
-- 
2.43.5