Porsche Wind Deflector with Edge Lighting [from CAD, prototyping to finish]

[Nine8Six]

Just dropping in some visuals of the prototype assy and how things works, where's the LED strip located, how heat xfers to the module, wiring, etc.

As you can see, edge lighting is one hell of an advanced technology and require a great deal of brain power. Already thinking of rising the price from $3,845 to $6,000. Some other good news, I'll be machining/anodizing the module's front and back covers during the beginning of this week so hopefully I'll have something to mount onto the glass by this coming weekend.

I'll update then!








^ The module's back cover is machined out of 6061 aluminum and is a one-piece part! That lip (what the LED strip sits onto) is what absorbs the energy/heat generated from the LEDs. With the wind/air hitting on the module's heatsink it should be more than sufficient cooling to keep those miniature LEDs cool and happy

[nieuwhzn]

Looks like you're having a lot of fun with SolidWorks, Fred.
Did you consider of doing a thermal simulation?

[Nine8Six]

Originally Posted by nieuwhzn

Looks like you're having a lot of fun with SolidWorks, Fred.
Did you consider of doing a thermal simulation?

Haha yes, better enjoying SW because HQ is making it redundant by 2015 :/ We're moving to AutoCAD Inventor seats (only) both at the R&D and manufacturing ends. No more him on SW, her on AutoCAD, them on Catia, etc.... e-v-e-r-y-b-o-d-y will need to cope with Autodesk by mid 2015. Go figure....

RE Simulation. I have the SW Simulation module running on my workstation however the Flow Simulation is not (needed for air cooling type sims). I do my own simulations however but mainly to gauge designs/shapes/parts vs their types of materials (e.g. fatigue, stress, etc). A thermal analysis coming from me would be totally redundant in this LED application. All I could do is highlight how heat is transferred from one end to another. Plain thermal loads, convections and/or radiation per material in both transient and steady states. Boring and rather useless... without air. Given aluminum dissipate heat 2,000x faster than any other composites (e.g. plastics)... we can call it a safe $3 worth of LED strip investment (I think!)

Beside, try asking a Chinese manufacturer what are the "convection coefficient" values in BTU of their super High Tech LED strips. Luck with that mate....lol

[Nine8Six]

On a far more important issue, I am having great difficulties selecting the right visual effect for the little guards red here. I kinda like the PORSCHE 986 best in all honesty but also like the one with the badge & Porsche (Bruce's). HELP! lol

Just throwing in these for inspiration. PM for the Illustrator/vector template if anyone is interested in making his/her own (I'll do those Made-to-Order no worries). Google "FREE VECTOR" for some ideas (tribal?)

[BruceH]

Originally Posted by Nine8Six

On a far more important issue, I am having great difficulties selecting the right visual effect for the little guards red here. I kinda like the PORSCHE 986 best in all honesty but also like the one with the badge & Porsche (Bruce's). HELP! lol

Just throwing in these for inspiration. PM for the Illustrator/vector template if anyone is interested in making his/her own (I'll do those Made-to-Order no worries). Google "FREE VECTOR" for some ideas (tribal?)

I agree with the others, I vote for the crest and lettering

[particlewave]

My vote(s).

Originally Posted by Nine8Six

[Nine8Six]

lol getting closer....

[jaykay]

Originally Posted by Nine8Six

Haha yes, better enjoying SW because HQ is making it redundant by 2015 :/ We're moving to AutoCAD Inventor seats (only) both at the R&D and manufacturing ends. No more him on SW, her on AutoCAD, them on Catia, etc.... e-v-e-r-y-b-o-d-y will need to cope with Autodesk by mid 2015. Go figure....

RE Simulation. I have the SW Simulation module running on my workstation however the Flow Simulation is not (needed for air cooling type sims). I do my own simulations however but mainly to gauge designs/shapes/parts vs their types of materials (e.g. fatigue, stress, etc). A thermal analysis coming from me would be totally redundant in this LED application. All I could do is highlight how heat is transferred from one end to another. Plain thermal loads, convections and/or radiation per material in both transient and steady states. Boring and rather useless... without air. Given aluminum dissipate heat 2,000x faster than any other composites (e.g. plastics)... we can call it a safe $3 worth of LED strip investment (I think!)

Beside, try asking a Chinese manufacturer what are the "convection coefficient" values in BTU of their super High Tech LED strips. Luck with that mate....lol

Wow I thought SW was the best out of the lot? What gives?

[Nine8Six]

Originally Posted by jaykay

Wow I thought SW was the best out of the lot? What gives?

I couldn't really comment on the move JK but let's just say there is nothing bad to say about any of those modern 3d solid software. Wouldn't want to be any senior mgt signing off on these changes/decisions - for whatever reason they may be

Today's solid software are all equally good - key players' of anyway. Autodesk, Dassault, etc... Don't under estimate Siemens NX and its add-ons, sinumerik ctrl tech i.e. design for manufacturing (ouch, game changer)

The're all excellent lol