CNC housing vs. extruded profile- Mtbr.com
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  1. #1
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    CNC housing vs. extruded profile

    Hello!

    I was thinking about a way to cut the cost of a housing. I must admit that $50-70 is expensive for a CNC aluminium housing for DIY projects with multiple MC-E/P7 emitters.

    Another possibility would be the Hammond boxes, but they don't have large heatsinking surfaces.

    So why not use extruded profiles like this one:

    for Achesalot-style builds?

    Or even better - design a custom extrusion specially for such lights?

  2. #2
    Experienced drunk cyclist
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    I must admit that $50-70 is expensive for a CNC aluminium
    Actually, $50-70 is dirt cheap for a custom made, purpose designed CNC housing. Have you ever tried to get quotes for CNC work?

    Secondly, having been involved in custom aluminium extrusions, I know how expensive it is to get the dies made for that type of work. Unless you are planning to make miles and miles of the stuff, the numbers just don't add up. Since every mile would be enough to make 10.000 lights, you'd need to sell quite a few.

    Cheers

    Cloggy

  3. #3
    Five is right out
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    Using smooth surfaces tends not to present heat dissipation problems. As long as you ride even slowly, you get enough airflow to keep most lights quite cool.

    Using something like that finned extrusion would probably make cooling even more effective. The downsides are the larger volume of the housing, and it's a PIA to cut through without powertools.

  4. #4
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    Yes, I know, the die cost in 2007 was around $1500-2000
    minimum order size was 500lb

    But I think that it is possible to use for our purpose some existing extrusions, like the one I posted above, but wider.

    BTW, the Dealextreme DIY E27 housing is an extrusion.
    http://www.dealextreme.com/details.dx/sku.13741

  5. #5
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    Yes, You are on right way
    Attached Images Attached Images

  6. #6
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    I made a MC-E light housing with 3 heatsinks(both side, behind LED) and 3 aluminum plate(upper, lower and back).

    New variant of Achesalot's way~.








    *) diagram



    This form can made double or triple light by using another size aluminum plate.
    Last edited by Narajjang; 03-05-2009 at 12:01 AM.

  7. #7
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    Well, custom extrusions are expensive even today.
    The die would cost $2000 and the minimum batch would be 500 kg @ $3.4/kg
    So the cost of a single run would be $3700 and that's without the cost of cutting. On the other hand, 500 kg of extrusions would give 9500 cases 5cm long each @ $1 piece !

    So the math shows that extruded cases are 20 times cheaper than CNC cases but the batch size is huge.

  8. #8
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    I'm planning on build a dual MCE when the budget is available. My idea is to maybe make separate housing out of round solid piece of rod that I cut fins and holes on a lathe.

    The $50-70 for cnc housing is cheap for a CNC housing but if you make something yourself you could get away lot cheap.

    Also while on the topic of housings. I have seen lot of you add big solid piece in the housings. Is this not actual bad for cooling cause a big piece takes longer to get hot but once hot it is harder to get cool down. Would a thin piece getting the heat to the cooling area not be better?

    Also I have not seen anybody using a small fan. Would it not maybe be a good idea seeing as one get tiny fans that pull very few power?

  9. #9
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    Quote Originally Posted by whattingh
    Also while on the topic of housings. I have seen lot of you add big solid piece in the housings. Is this not actual bad for cooling cause a big piece takes longer to get hot but once hot it is harder to get cool down. Would a thin piece getting the heat to the cooling area not be better?
    I think the extra mass helps to lower the max temperature, for when the light has no cooling airflow. It depends on the construction, if its an extra piece between the LEDs and exterior it will increase the normal led temperature. Thats the good thing about extrusions, direct thermal path to the exterior.

    On extrusions....
    Finding just the right extrusion, one that perfectly fits your LEDs, optics, drivers and switches a is truly a wonderful thing.

  10. #10
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    Quote Originally Posted by whattingh
    I'm planning on build a dual MCE when the budget is available. My idea is to maybe make separate housing out of round solid piece of rod that I cut fins and holes on a lathe.

    The $50-70 for cnc housing is cheap for a CNC housing but if you make something yourself you could get away lot cheap.

    Also while on the topic of housings. I have seen lot of you add big solid piece in the housings. Is this not actual bad for cooling cause a big piece takes longer to get hot but once hot it is harder to get cool down. Would a thin piece getting the heat to the cooling area not be better?

    Also I have not seen anybody using a small fan. Would it not maybe be a good idea seeing as one get tiny fans that pull very few power?
    Yes It can be done very cheap, it all depends how much work you want to do.

    I bought enough 41mm bar to make 2 housings for only 8.00 including post from an ebay shop. But if time is money then the time they took to make would make them more expensive than the CNC option.( I enjoy doing it so for me it isn't work).

    With regard to fans, people have had a go but I think if the light gets so hot as to require one then it should be back to the drawing board and design a better heatsink.

    4.00 per housing
    Last edited by yetibetty; 03-23-2009 at 10:23 AM.

  11. #11
    Spanish biker
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    Quote Originally Posted by yetibetty
    Yes It can be done very cheap, it all depends how much work you want to do.

    I bought enough 41mm bar to make 2 housings for only 8.00 including post from an ebay shop. But if time is money then the time they took to make would make them more expensive than the CNC option.( I enjoy doing it so for me it isn't work).

    With regard to fans, people have had a go but I think if the light gets so hot as to require one then it should be back to the drawing board and design a better heatsink.

    4.00 per housing
    Wowwwww, very cheap and very nice!!!!!!!

    Could you tell me how measure in mm the end cap, please?

    Greetings .- Saludos

    msxtr
    Warning!!! my english is very very bad, sorry.

    Easy DIY led light1
    Easy DIY led light2

    The Beast!!!

  12. #12
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    Quote Originally Posted by msxtr
    Wowwwww, very cheap and very nice!!!!!!!

    Could you tell me how measure in mm the end cap, please?

    Greetings .- Saludos

    msxtr
    msxtr, is this OK or did I misunderstand?
    Last edited by yetibetty; 03-23-2009 at 10:23 AM.

  13. #13
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    This extrusion looks like a good candidate:

    (detailed drawing here - https://chipdip.ru/library/DOC000156671.jpg)
    cut in 5cm pieces the price would be $0.6 per piece (without the cost of cutting)

    But it is too large. Has anybody seen a similar extrusion but smaller?

  14. #14
    aka RossC
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    YB, that is gorgeous. well done!

  15. #15
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    Quote Originally Posted by yetibetty
    msxtr, is this OK or did I misunderstand?
    Thank you very much!!!!!!

    Greetings - Saludos

    msxtr
    Warning!!! my english is very very bad, sorry.

    Easy DIY led light1
    Easy DIY led light2

    The Beast!!!

  16. #16
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    YB, How do you mount it?

  17. #17
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    Quote Originally Posted by whattingh
    YB, How do you mount it?
    Exposure quick release, very expensive but very nice.

    http://www.chainreactioncycles.com/M...?ModelID=22858
    Last edited by yetibetty; 03-23-2009 at 10:23 AM.

  18. #18
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    Sweet

    thanks

  19. #19
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    Quote Originally Posted by zemike
    This extrusion looks like a good candidate:

    (detailed drawing here - https://chipdip.ru/library/DOC000156671.jpg)
    cut in 5cm pieces the price would be $0.6 per piece (without the cost of cutting)

    But it is too large. Has anybody seen a similar extrusion but smaller?
    Too large? No, that's the perfect housing for 80 XP-Es That would be considered a weapons-grade light.

    JZ
    It's not about speed, it's about lack of control.

  20. #20
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    Last edited by yetibetty; 03-23-2009 at 10:22 AM.

  21. #21
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    Is there a place to find the extrusions other than Russia? I wouldn't mind trying them as cooling fins on an aluminum housing.

  22. #22
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    Quote Originally Posted by .40AET
    Is there a place to find the extrusions other than Russia?
    Not a problem at all.
    Check this manufacturer - http://www.hammondmfg.com/sinkbox.htm

    Sincerely I must admit that China can be a good source of such extrusions.

  23. #23
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    Quote Originally Posted by yetibetty
    Well, those are not die cast, but extruded.
    This one is a good one: http://tp01.com/estore/product_info....products_id=58 but they can be found for cheaper.

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