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Flat Crunch Lantern - Flashlight Diffuser

Created as a challenge to make a 'weird' flashlight diffuser with function.
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updated September 5, 2022

Description

PDF

See it in action - https://www.youtube.com/watch?v=6uOr2lsWAE8

Current sizes:
14mm - Lots of AAA sized lights
24mm - Wurkkos FC11, S2+
25.5 - FW3A
26.6 - S21A
28mm - Emisar D4V2
28.5mm - Noctigon KR4 (even though the bezel is 29mm, this is smaller to offset the taper)
39mm - Emisar D4SV2
49mm - Sofirn SP36
50mm - SP36
52mm - Outdoor International K9.3
49mm - Sofirn Q8
63mm - DM1.12

DT8, this is weird and special, print both the diffuser and the strap.

Please let me know if you want to see an STL for a different light. I strongly suggest you provide bezel diameter if you would like something custom.

This must be printed in TPU. Use a dry filament with a pretty locked in profile. Otherwise the latching mechanism will have difficulties. The latch is intentionally tight.

You will need support for the cutout. It can be from bed only and make sure you change the support angle so you only have that tiny area supported. No need to mess with supporting the pleats.

.2mm layer height worked fine. I also went wide with my line width @ .55 get lots of perimeters/walls so you don't have to deal with inconsistent infill on the lantern section. I believe you could print this at other widths/heights, but pay attention if you slicer starts doing dumb things.

Print slow for a good clean print or make an ugly print, your choice.

 

Post-Printing

 

If you and your TPU profile are in harmony, just rip off the tiny support and it is good to go. Otherwise, clip, burn and pick at your print until it does what you want.

 

How I Designed This

 

Parametric design in Fusion 360. I can change any dimension pretty easily other than the number of pleats. If you REALLY had a wild idea let me know.

 

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