My Case Idea

[danielbriggs]

Hi Guys,
Been doing a bit of thinking on my build; specifically the case. I originally had a doubled deck'd box in mind, however I wanted something a little bit more off the wall (no offence)

This is still very much in 'on paper' phase, and will remain so until at least after the LM (where my build plans will no doubt change ). But I'll just outline what I'm planning with the case, and your thoughts and feedback are greatly welcomed.

In short: Think of a giant toblerone
In detail: I want to make a large equilateral-triangle shaped prism with two levels in it. The larger base level with all the lasers, galvo's and optics in, and the smaller top level with the PSU's, Amps and FB3.
I want this to be fairly narrow, but be fairly long.
Both the bottom and top base plate will be 12mm+ thick aluminium, with several large posts at regular intervals to maintain rigidity between the levels. There will then be 2 side plates, made from 3mm thick sheet which are connected together via a long piano hinge stretching the full length of the build, and this assembly itself hinged to the bottom base plate, with a latch on the other side. This will then let me 'open the hood' full, giving full access to both levels from every angle, and can be swung shut and locked when operating etc...
There will be two triangular fixed vertical plates (10mm) for the front and rear ends of the build, one will have the cut outs for the switches, plugs, locks etc. al at the back, and the other will have an aperture (about 60mm or something at the front to let the light out).
The laser modules will be arrange perpendicular to the output beam path, e.g. on the right edge, with the optics+dichro's on the left hand side. A mirror at the front will correct the 90deg and pass the beams to the galvo's positioned in the middle near the output aperture.
Just some rough figures, I think about 300mm wide baseplate at the bottom, and 900mm long will suffice. However if I need more space on one of the levels, the others will increase as needed according to trig.
Also, just for the top level, I can drill and mount an 40/60/80mm fan at either end to provide a 'wind tunnel' cooling thing. Which won't get dust build up on the optics etc...

I whipped up a VERY crude, 2 min jobby in CAD to show a little bit of what I mean. (posts omitted - amungst other things) The real unit will be longer, I just didn't extrude the model enough.

So what do you all think?
Should I pursue this path, or is there some glaringly obvious no-no I'm missing?
Personally, I like it! And I'm gonna have fun building it!
Remember, you saw it here first!

Dan

[White-Light]

I like the idea, laser meets art deco!

How easy it is to make is another matter. If 3 separate pieces of sheet you're going to need corner lengths machine bent to exactly the correct angle, so you're probably going to have to find someone with a computer controlled folding machine unless you're lucky enough to find someone who makes these angles off the shelf. The edges of the sheet will have to be cut to match as well so you don't get wide seams where they meet.

Also, I'd think you want to keep as may of the heat producing components on the bottom deck as possible as the pointed roof is likely to channel and concentrate heat quite strongly in the apex.

The bracket arrangement is likely to be quite interesting and have to be triangulated too. I'd imagine a rectangular frame (to give room to turn the bracket screws) attached as a kind of a t shape to a central post with triangular supporting arms mirroring the box as strengthening pieces.

Just my initial thoughts as a non-experienced builder though. Others may know of other pitfalls or of better ideas for achieving the same.

[danielbriggs]

Thanks for your reply - it's all going to be made from individual flat sheet pieces - no folding necessary at all. I'll just have to cut a 60deg edge on the 12mm plates. The thin side plates are hinged and can be open or closed with a latch - they won't be directly bolted down.

[Stuka]

Whoa -

Shades of Pink Floyd, even without the lasers turned on!!

Cool...

[allthatwhichis]

Nice! I had a similar idea but no clue on how to even express it to have the idea debated. Thanks! I bet it would never tip over.

[majorlee]

in which way would you consider the mountings for the unit?

looks very nice tho

[danielbriggs]

Whoa -

Shades of Pink Floyd, even without the lasers turned on!!

Cool...

LOL! I didn't realise that until you said it! I like!

in which way would you consider the mountings for the unit?

looks very nice tho

Do you mean the laser modules or the support posts?
The laser modules will be at right angles to the length of the case, and the support posts will be placed (either cylinders or triangular struts) in several places along the side.

Ta,
Dan

[buffo]

Hi Dan;

That would be a very unique layout! While it's not as efficient as other designs, I don't see any reason why it wouldn't work.

One thing to consider: How are you going to mount it? Are you planning on always setting the unit on a table or flat stand, or will you ever need to hang it from a light bar or truss? Hanging such a projector would appear to be difficult...

I don't think heat will be too large of an issue so long as you have some air flow through the top level of the case. Might get a little cramped up there though, since the top level will be ~ half the size of the bottom plate. But yeah, it's doable.

If you do decide to go this route, be sure to take lots of pictures! Like I said, it would certainly be one of the most unique projectors on PL. Also, I like Aaron's point that it's got shades of Pink Floyd even when it's off!

Adam

[Laserman532]

very cool shape, and if you find out you dont like it, add a few wood shingles and it would make a wonderful bird house

[danielbriggs]

One thing to consider: How are you going to mount it? Are you planning on always setting the unit on a table or flat stand, or will you ever need to hang it from a light bar or truss? Hanging such a projector would appear to be difficult...

Yeah, I sort of realised that as an after thought, but I've not specifically designed it to be 'club ready' so to speak. I think if I just have it sat on a table, perhaps with screw post feet (like on LCD projectors) so I can alter the angle higher or lower. It'll do for a 'hobby' build

I don't think heat will be too large of an issue so long as you have some air flow through the top level of the case. Might get a little cramped up there though, since the top level will be ~ half the size of the bottom plate. But yeah, it's doable.

My thoughts exactly, I'm not going to build this until I have all the lasers et. al. I need working on my desk, then I'll plan the case dimensions around that. So we won't be seeing it in the flesh for at least a few months
A few fans at either end like you said should keep the air moving through the PSU's.
I've been roughly pricing it up, and it's gonna cost a fair bit in ally plate, but this is necessary to the build

If you do decide to go this route, be sure to take lots of pictures!

Don't you mean when I go this route! I assure you Adam, I'll take photos a plenty, and I'll stick the plans up hopefully when finalised, so other people can re-use the design.


Cheers,
Dan