Gobo / Aperture for Defiant LED Light (concept)

It is likely that few people own the Defiant LED light that I used to design this model. So, this design is more of a idea than a specific model that people would be interested in printing, but the concept could be adapted for many different lights and gobo / aperture shapes.

I wanted an easy-to-use, portable LED light that would emit a rectangular pattern so that I could illuminate a chalkboard, from close proximity, while having the room lights turned off. However, I did not want to light to bleed out much beyond the borders of the chalkboard. I have an LED work light, but it emits a round beam. So, I made this simple base that fit on an that light, an older Defiant LED light (from Home Depot - the newer/current models are different). I simply taped it on to the light. Then, I made a gobo /aperture / lens section that fit inside the base's cylinder (0.5mm difference between the I.D and the O.D.). The lens moves in and out of the base's cylinder like a telephoto lens (sort of).

Based on the dimensions of the chalkboard, I designed in a moderately trapezoidal opening in the face of the gobo to account for the keystone effect that occurs when a rectangular light is shown on on a flat surface from an angle (I positioned the light to be shining a little lower than on center for the board). I made it so that the gobo lens could be pulled in and out to adjust the size of the projected rectangle. The edges of the projected rectangle were somewhat blurry, but acceptable. For more precise edges, the lens/gobo shape needs to be farther away from the light source (a longer throw), but I was okay with a fairly short throw, and a little blurry edges. I did design in slots, of sorts, to keep the gobo / aperture lens aligned.

I printed these two pieces at 100% infill, 0.4mm nozzle, 0.2mm layer height.