Mini Theatre Lights

The idea was to make miniature spotlights that can be controlled via a standard lighting controller, like the one we use in the theatre I'm working at.
You can open and close the barndoors, as well as move the whole spotlight around, just like a normal sized one.
The spotlights are fully RGB, can be controlled trough a DMX port on the side of the control box and are individually addressable (3 addresses per Spotlight), allowing for cool effects.
However it is also possible to use them in manual mode, using three potentiometers to control hue, saturation and value (brightness).
In theory the setup can me scaled to allow for many more spotlights, although minor changes in software could be necessary.
I use them as a fun desk lamp, but your imagination is the limit (maybe a fully functioning miniature theatre?).

Print instructions

Printing

The spotlight can be printed with PLA (the LEDs emit almost no heat) and without supports. It is advisable to print the part that holds the LED with clear filament, as it looks a lot better.
For the controlbox supports could be necessary to ensure that the holes are clean.
The 3d model for the truss can be found here.
To print them without supports drop the temp a little, to ensure clean bridging (Prusament PLA).
Here you can find the spotlight model I modified for my use.

Partslist

Spotlight (for 1)

• printed parts
  
• 1 PL9823 LED 8mm
  
• 2 M2,5*6 screws
  
• 1 M2,5*16 screw
  
• 1 M2,5 locknut
  
• glue
  
• aluminum tape
  
• 1,5mm craft wire
  
• 1 3,3-10ohm resistor
  
• 1 100nF capacitor
  
• 4 M2,7 washers (optional)
  
  
  Controlbox
  
• printed parts
  
• 4 M2,5*6 screws (for the lid)
  
• 1 10*5cm PCB
  
• 3 M2*6 screws (to hold the PCB)
  
• 3 B10K potentiometers (1 of them preferably a slide pot)
  
• 1 male DMX socket
  
• 1 DC socket
  
• 2 switches
  
• 1 small red LED + high resistor (optional)
  
• 2 arduinos (in my case nano)
  
• 2 4k7ohm resistors
  
• 1 Max485 module
  
  
  Misc
  
• solder/soldering iron
  
• a lot of 18AWG wire (multicolour is helpful)
  
• 5V DC powersupply
  
• tools (pliers, drill, small knife,tweezers etc.)
  
  

Assembly

I included a schematic for the wiring in the photos.

Spotlight:

Take the LED and glue it into the LED holder. Clip off the Vcc pin and solder on the resistor. Place the capacitor between Vcc and Gnd pin and solder it on (see picture). The resistor and capacitor are there to reduce noise from the microcontrollers in the LED. You can secure the pin connections with some hot glue, but be careful not to overheat the plastic. Now solder on the 18AWG wire.
Pull the wire through the back of the spotlight and sercure the led holder with a little glue.
Put some aluminum tape into the front half and attach the barn doors with the craft wire. Take the two halves of the spotlight and press them together (should be a pressfit, otherwise use glue).
When you make multiple lights be aware that the ground and power wires need to be looped through to the next light.
Attach the spotholder with M2,5*6 screws with optional washers between the printed parts. Use the other screw with the locknut
with the remaining parts to secure the spotlight on the truss.

Controlbox:

Solder everything on the PCB according to the schematic (hopefully the photo helps). I used risers for the arduinos, so you can take them out and reprogram them if needed.
The potentiometers and one switch are attached to the lid.
At last close the lid with 4 screws.
The code for the arduinos can be found here.

If you only want the manual control, one arduino can be omitted, although minor hardware and software changes are necessary.

I think in the future, the controlbox design can be slimmed down a lot. Maybe also add a dipswitch to chose the starting adress.

Thanks for reading