The New Hotness

Dropping a simplified ping-pong ball radome for a Piranha RGB LED atop a discrete LM3909 on the AA alkaline cell holder:

Discrete LM3909 Radome - AA alkaline — Discrete LM3909 Radome – AA alkaline

The solid model has screw holes for the lid and the revised LED spider:

Astable Multivibrator - Alkaline AA Base - radome - solid model — Astable Multivibrator – Alkaline AA Base – radome – solid model

The RGB LED needs only two wires, as the LM3909 circuit can blink only one LED. I tried all three colors, but only blue and green justify the LM3909 hairball; red can get along with the astable circuit.

The LED wires connect across a 1 MΩ resistor serving as a mechanical strut between the 9.1 kΩ resistor on the left and the 10 Ω ballast resistor on the right.

Fresh alkaline cells at 3.0 V put 3.3 V across the blue LED with a 37 mA peak current. Older cells at 2.3 V produce 2.9 V at 15 mA. Dead cells at 1.9 V still fire the LED with 2.7 V at 4.2 mA, although the flash is barely visible in ordinary room light.

The lovely blue ball looks better in person!

The OpenSCAD source code as a GitHub Gist:

	// Astable Multivibrator
	// Holder for Alkaline cells
	// Ed Nisley KE4ZNU August 2020
	// 2020-09 add LED radome

	/* [Layout options] */

	Layout = "Build"; // [Build,Show,Lid,Spider]

	/* [Hidden] */

	CellName = "AA"; // [AA] — does not work with anything else
	NumCells = 2; // [2] — likewise

	Struts = -1; // [0:None, -1:Dual, 1:Quad] — Quad is dead

	// Extrusion parameters

	/* [Hidden] */

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
	function IntegerLessMultiple(Size,Unit) = Unit * floor(Size / Unit);

	Protrusion = 0.1; // make holes end cleanly

	inch = 25.4;

	//- Basic dimensions

	WallThick = IntegerMultiple(3.0,ThreadWidth);
	CornerRadius = WallThick/2;

	FloorThick = IntegerMultiple(3.0,ThreadThick);

	TopThick = IntegerMultiple(2.0,ThreadThick);

	WireOD = 1.5; // battery & LED wiring
	WireOC = 4;

	Gap = 5.0;

	// Cylindrical cell sizes
	// https://en.wikipedia.org/wiki/List_of_battery_sizes#Cylindrical_batteries

	CELL_NAME = 0;
	CELL_OD = 1;
	CELL_OAL = 2;

	// FIXME search() needs special-casing to properly find AAA and AAAA
	// Which is why CellName is limited to AA

	CellData = [
	["AAAA",8.3,42.5],
	["AAA",10.5,44.5],
	["AA",14.5,50.5],
	["C",26.2,50],
	["D",34.2,61.5],
	["A23",10.3,28.5],
	["CR123A",17.0,34.5],
	["18650",18.8,65.2], // bare 18650 with button end
	["18650Prot",19.0,70.0], // protected 18650 = 19670 plus a bit
	];

	CellIndex = search([CellName],CellData,1,0)[0];
	echo(str("Cell index: ",CellIndex," = ",CellData[CellIndex][CELL_NAME]));

	//- Contact dimensions

	CONTACT_NAME = 0;
	CONTACT_WIDE = 1;
	CONTACT_HIGH = 2;
	CONTACT_THICK = 3; // plate thickness
	CONTACT_TIP = 4; // tip to rear face
	CONTACT_TAB = 5; // solder tab width

	ContactData = [
	["AA+",12.2,12.2,0.3,1.7,3.5], // pos bump
	["AA-",12.2,12.2,0.3,5.0,3.5], // half-compressed neg spring
	["AA+-",28.2,12.2,0.3,5.0,0], // pos-neg bridge

	["Li+",18.5,16.0,0.3,2.8,5.5],
	["Li-",18.5,16.0,0.3,6.0,5.5],
	];

	function ConDat(name,dim) = ContactData[search([name],ContactData,1,0)[0]][dim];

	ContactRecess = 2*ConDat(str(CellName,"+"),CONTACT_THICK);
	ContactOC = CellData[CellIndex][CELL_OD];

	WireBay = 6.0; // room for wiring to contacts

	//- Wire struts

	StrutDia = 1.6; // AWG 14 = 1.6 mm
	StrutSides = 3*4;

	ID = 0;
	OD = 1;
	LENGTH = 2;

	StrutBase = [StrutDia,StrutDia + 25ThreadWidth, // ID = wire, OD = buildable
	FloorThick + CellData[CellIndex][CELL_OD]]; // LENGTH = base is flush with cell top

	//- Holder dimensions

	BatterySize = [CellData[CellIndex][CELL_OAL] + // cell
	ConDat(str(CellName,"+"),CONTACT_TIP) + // pos contact
	ConDat(str(CellName,"-"),CONTACT_TIP) – // neg contact
	2*ContactRecess, // sink into wall
	NumCells*CellData[CellIndex][CELL_OD],
	CellData[CellIndex][CELL_OD]
	];

	echo(str("Battery space: ",BatterySize));

	CaseSize = [3*WallThick + // end walls + wiring partition
	BatterySize.x + // cell
	WireBay, // wiring bay
	2*WallThick + BatterySize.y,
	FloorThick + BatterySize.z
	];

	BatteryOffset = (CaseSize.x – (2*WallThick +
	CellData[CellIndex][CELL_OAL] +
	ConDat(str(CellName,"-"),CONTACT_TIP))
	) /2 ;

	ThumbRadius = 0.75 * CaseSize.z;


	StrutOC = [IntegerLessMultiple(CaseSize.x – 2CornerRadius -2StrutBase[OD],5.0),
	IntegerMultiple(CaseSize.y + StrutBase[OD],5.0)];

	StrutAngle = atan(StrutOC.y/StrutOC.x);

	echo(str("Strut OC: ",StrutOC));

	LidSize = [2*WallThick + WireBay + ConDat(str(CellName,"+"),CONTACT_THICK), CaseSize.y, FloorThick/2];

	LidScrew = [2.0,3.8,7.0]; // M2 pan head screw (LENGTH = threaded)
	LidScrewOC = CaseSize.y/2 – CornerRadius – LidScrew[OD]; // allow space around screw head

	//- Piranha LEDs

	PiranhaBody = [8.0,8.0,8.0]; // Z = heatsink fins + body + lens height

	PiranhaPin = 0.0; // trimmed pin length beyond heatsink
	PiranhaPinsOC = [5.0,5.0]; // pin XY distance

	PiranhaRecess = PiranhaBody.z + PiranhaPin/2; // minimum LED recess depth

	BallOD = 40.0; // radome sphere
	BallSides = 4*StrutSides; // nice smoothness

	BallPillar = [norm([PiranhaBody.x,PiranhaBody.y]), // ID
	norm([PiranhaBody.x,PiranhaBody.y]) + 3*WallThick, // OD
	StrutBase[OD] + PiranhaBody.z]; // height to base of chord
	echo(str("Pillar OD: ",BallPillar[OD]));

	BallChordM = BallOD/2 – sqrt(pow(BallOD/2,2) – (pow(BallPillar[OD],2))/4);
	echo(str("Ball chord depth: ",BallChordM));


	//———————-
	// Useful routines

	module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes

	Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);

	FixDia = Dia / cos(180/Sides);

	cylinder(r=(FixDia + HoleWindage)/2,h=Height,$fn=Sides);
	}

	// Spider for single LED atop struts, with the ball

	module DualSpider() {

	difference() {
	union() {
	for (j=[-1,1]) {
	translate([0,j*StrutOC.y/2,StrutBase[OD]/2])
	rotate(180/StrutSides)
	sphere(d=StrutBase[OD]/cos(180/StrutSides),$fn=StrutSides);
	translate([0,j*StrutOC.y/2,0])
	rotate(180/StrutSides)
	cylinder(d=StrutBase[OD],h=StrutBase[OD]/2,$fn=StrutSides);
	}

	translate([0,0,StrutBase[OD]/4]) // connecting bars
	cube([StrutBase[OD]*cos(180/StrutSides),StrutOC.y,StrutBase[OD]/2],center=true);

	cylinder(d=BallPillar[OD],h=BallPillar[LENGTH],$fn=BallSides);
	}

	for (j=[-1,1]) // strut wires
	translate([0,j*StrutOC.y/2,-Protrusion])
	PolyCyl(StrutBase[ID],StrutBase[OD]/2,6);

	for (n=[-1,1]) // LED wiring
	rotate(n*90)
	translate([StrutOC.x/3,0,-Protrusion])
	PolyCyl(StrutBase[ID],StrutBase[OD],6);

	translate([0,0,BallOD/2 + BallPillar[LENGTH] – BallChordM]) // ball inset
	sphere(d=BallOD);

	translate([0,0,BallPillar.z – PiranhaRecess + BallPillar.z/2]) // LED inset
	cube(PiranhaBody + [HoleWindage,HoleWindage,BallPillar.z],center=true); // XY clearance

	translate([0,0,StrutBase[OD]/2 + WireOD/2 + 0*Protrusion]) // wire channels
	cube([WireOD,BallPillar[OD] + 2*WallThick,WireOD],center=true);

	}
	}

	//– Overall case with origin at battery center

	module Case() {

	union() {

	difference() {
	union() {
	hull()
	for (i=[-1,1], j=[-1,1])
	translate([i*(CaseSize.x/2 – CornerRadius),
	j*(CaseSize.y/2 – CornerRadius),
	0])
	cylinder(r=CornerRadius/cos(180/8),h=CaseSize.z,$fn=8); // cos() fixes undersize spheres!

	if (Struts)
	for (i = (Struts == 1) ? [-1,1] : -1) { // strut bases
	hull()
	for (j=[-1,1])
	translate([iStrutOC.x/2,jStrutOC.y/2,0])
	rotate(180/StrutSides)
	cylinder(d=StrutBase[OD],h=StrutBase[LENGTH],$fn=StrutSides);

	translate([i*StrutOC.x/2,0,StrutBase[LENGTH]/2])
	cube([2*StrutBase[OD],StrutOC.y,StrutBase[LENGTH]],center=true); // blocks for fairing

	for (j=[-1,1]) // hemisphere caps
	translate([i*StrutOC.x/2,
	j*StrutOC.y/2,
	StrutBase[LENGTH]])
	rotate(180/StrutSides)
	sphere(d=StrutBase[OD]/cos(180/StrutSides),$fn=StrutSides);

	}
	}

	translate([BatteryOffset,0,BatterySize.z/2 + FloorThick]) // cells
	cube(BatterySize + [0,0,Protrusion],center=true);

	translate([BatterySize.x/2 + BatteryOffset + ContactRecess/2 – Protrusion/2, // contacts
	0,
	BatterySize.z/2 + FloorThick])
	cube([ContactRecess + Protrusion,
	ConDat(str(CellName,"+-"),CONTACT_WIDE),
	ConDat(str(CellName,"+-"),CONTACT_HIGH)
	],center=true);

	translate([-(BatterySize.x/2 – BatteryOffset + ContactRecess/2 – Protrusion/2),
	ContactOC/2,
	BatterySize.z/2 + FloorThick])
	cube([ContactRecess + Protrusion,
	ConDat(str(CellName,"+"),CONTACT_WIDE),
	ConDat(str(CellName,"+"),CONTACT_HIGH)
	],center=true);

	translate([-(BatterySize.x/2 – BatteryOffset + ContactRecess/2 – Protrusion/2),
	-ContactOC/2,
	BatterySize.z/2 + FloorThick])
	cube([ContactRecess + Protrusion,
	ConDat(str(CellName,"-"),CONTACT_WIDE),
	ConDat(str(CellName,"-"),CONTACT_HIGH)
	],center=true);

	translate([-CaseSize.x/2 + WireBay/2 + WallThick, // wire bay with screw bosses
	0,
	BatterySize.z/2 + FloorThick + Protrusion/2])
	cube([WireBay,
	2LidScrewOC – LidScrew[ID] – 24*ThreadWidth,
	BatterySize.z + Protrusion
	],center=true);

	for (j=[-1,1]) // screw holes
	translate([-CaseSize.x/2 + WireBay/2 + WallThick,
	j*LidScrewOC,
	CaseSize.z – LidScrew[LENGTH] + Protrusion])
	PolyCyl(LidScrew[ID],LidScrew[LENGTH],6);


	for (j=[-1,1])
	translate([-(BatterySize.x/2 – BatteryOffset + WallThick/2), // contact tabs
	j*ContactOC/2,
	BatterySize.z + FloorThick – Protrusion])
	cube([2*WallThick,
	ConDat(str(CellName,"+"),CONTACT_TAB),
	(BatterySize.z – ConDat(str(CellName,"+"),CONTACT_HIGH))
	],center=true);

	if (false)
	translate([0,0,CaseSize.z]) // finger cutout
	rotate([90,00,0])
	cylinder(r=ThumbRadius,h=2*CaseSize.y,center=true,$fn=22);

	translate([0,0,ThreadThick – Protrusion]) // recess around name
	cube([0.6CaseSize.x,8,2ThreadThick],center=true);

	if (Struts)
	for (i2 = (Struts == 1) ? [-1,1] : -1) { // strut wire holes and fairing
	for (j=[-1,1])
	translate([i2StrutOC.x/2,jStrutOC.y/2,FloorThick])
	rotate(180/StrutSides)
	PolyCyl(StrutBase[ID],2*StrutBase[LENGTH],StrutSides);

	for (i=[-1,1], j=[-1,1]) // fairing cutaways
	translate([iStrutBase[OD] + (i2StrutOC.x/2),
	j*StrutOC.y/2,
	-Protrusion])
	rotate(180/StrutSides)
	PolyCyl(StrutBase[OD],StrutBase[LENGTH] + 2*Protrusion,StrutSides);
	}

	}

	translate([0,0,0])
	linear_extrude(height=2*ThreadThick + Protrusion,convexity=10)
	mirror([0,1,0])
	text(text="KE4ZNU",size=6,spacing=1.20,font="Arial:style:Bold",halign="center",valign="center");

	}
	}


	module Lid() {

	difference() {
	hull()
	for (i=[-1,1], j=[-1,1], k=[-1,1])
	translate([i*(LidSize.x/2 – CornerRadius),
	j*(LidSize.y/2 – CornerRadius),
	k*(LidSize.z – CornerRadius)]) // double thickness for flat bottom
	sphere(r=CornerRadius/cos(180/8),$fn=8);

	translate([0,0,-LidSize.z]) // remove bottom
	cube([(LidSize.x + 2Protrusion),(LidSize.y + 2Protrusion),2*LidSize.z],center=true);

	for (j=[-1,1]) // wire holes
	translate([0,j*WireOC,-Protrusion])
	PolyCyl(WireOD,2*LidSize.z,6);

	for (j=[-1,1])
	translate([0,j*LidScrewOC,-Protrusion])
	PolyCyl(LidScrew[ID],2*LidSize.z,6);

	}
	}


	//——————-
	// Build it!

	if (Layout == "Case")
	Case();

	if (Layout == "Lid")
	Lid();

	if (Layout == "Spider")
	if (Struts == -1)
	DualSpider();
	else
	cube(10,center=true);

	if (Layout == "Build") {
	rotate(90)
	Case();
	translate([0,-(CaseSize.x/2 + LidSize.x/2 + Gap),0])
	rotate(90)
	Lid();
	if (Struts == -1)
	translate([CaseSize.x/2,0,0])
	DualSpider();
	}

	if (Layout == "Show") {
	Case();
	translate([-CaseSize.x/2 + LidSize.x/2,0,(CaseSize.z + Gap)])
	Lid();
	}

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The New Hotness

Discrete LM3909: Blue LED Radome