DIY LED reflector, how to design one?

PeterFH

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Sep 23, 2016
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Hello!
For my current project i could use a few LED reflectors, since i can not find one that is to my liking i would like to build one my own.
The idea is to build a stamping form tool with my 3D printer and stamp out a few out of thin Aluminium sheet material.
But i got a hard time to figure out the curvature of the reflector, after i asked google i feel like i am in 5th grade math class again.

Is there any way to make this a bit easier?
I would like to calculate the ideal form of the mirror instead of just roughly guesstimating something, my CAD program is Fusion360.

Thank you in advance!

Greetings,
Peter
 

PeterH

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Aug 31, 2010
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What kind of throw pattern are you looking for? For good throw you're looking for a parabola. For a wider pattern the shape can be less critical. For most high power LEDs I've seen the intensity follows cos(A), where A is the angle away from straight out.

For validating a pattern I've had good results with POVRay. Yes, a computer graphics program. But there's a bit of a learning curve involved.
 

DrafterDan

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Phoenix, AZ
More importantly, have you a process for achieving a flawless mirrored surface? Or a textured pattern, but it should be awesome, otherwise why put forth the effort
 

PeterFH

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Sep 23, 2016
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Thanks for the replys!

What kind of throw pattern are you looking for?

After a bit of fiddling with foil, tape and thin aluminium sheet i came to the conclusion that it is far less critical then i thought.
Pretty much anything shiny at a rough angle on the sides will do what i want.

More importantly, have you a process for achieving a flawless mirrored surface? Or a textured pattern, but it should be awesome, otherwise why put forth the effort

No need for a flawless finish, i want to make it myself because buying something pre-made is booring, i can not learn anything and because building things is fun.
 

UrbanExplorer

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Feb 16, 2017
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California.
I happen to be doing the exact same thing. I'm going to make mine out of cardboard (cereal box kind) and layer it in a Mylar blanket. Works great. As for the parabolic shape it's a tad complicated so PM if you're still interested.
 
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