100W Big LED and Lens Enclosure

This enclosure fits the big-style (like 100W) LED modules with the reflector and lens as separate parts. The design can be used as-is or easily modified and integrated into other projects.

The problem with these things is that the parts (LED, reflector, lens, retainer) don't screw onto one another, and depend on an enclosure or frame in order to assemble into one piece. This makes it harder to use in projects.

The bottom piece holds everything, and the channels are for routing wires (you can zig-zag wires around for strain relief, too.) The top part is just a cover and screws into the bottom.

You can use some, all, or none of the M3-sized holes for mounting the parts.

A (mostly-error-free!) exported STEP file is provided for those who would prefer to modify a CAD model.

A NOTE ABOUT HEAT SINKING:
This design is intended for heatsink-free operation. There is no heat sink provided or allowed for in this design. Either chop a hole and add your own, or use the LED only sparingly so that heat is not a concern (my project used it as a momentary strobe flash, so no heat sink needed.) If you're building a lamp or other constant-on lighting project, you will need a heat sink.

Print instructions

ledbox.3mf -- this file has both parts oriented for printing, and if printed sequentially (print one then print the other) they are far enough apart that it will work fine.

ledbox-top.stl and -bottom.stl -- STL exports for those who prefer STL files.

100w_big_led_assembly.stp -- STEP format CAD file for modification and tampering.

Both parts should be printed with the smoothest side down on the build platform.

You can optionally print with supports turned on (supports only on build platform works well) to make the holes a bit prettier.