welcome back to another episode and i think you're really gonna like this one
i'm taking a bunch of scrap metal and turning it into a finished functioning part
all in one video what i'm about to show you is part of a larger project that i've been
working on for about four or five years now i'm currently building a very powerful light engine
with a very high cri the experimental chip that i'm using creates so much light
and so much heat in such a small package there was a thermal engineering challenge to make this work
it was such a challenge that this chip has never been ran full power before for more than a few
seconds i'm hoping to change that i'm going to show you the entire process how i design
it how i build it how i machine it the whole thing the only thing i can't show you is the
actual chip that i'm using since it is in the experimental stage may sound crazy but let's go
this right here is a solid piece of ar06 12 micron graphite
it looks like it's all done machining and there's conductive carbon dust everywhere
but let's clean the part off see how it looks here's the finished mold uh came out pretty good
you're looking at 10 hours of straight machining right here and it came out so
pretty that i'm really regretting using the one piece of graphite it was all chipped up
because other than that it came out absolutely perfect one thing about this graphite watch this
this is a table that's about 25 feet away from the milling machine and even though
i was using an extractor the dust is just so fine it gets everywhere now comes the
tricky part to try and cast it now i need to know how much copper to put in my crucible
and to figure that out quickly i'm going to jump back in fusion 360
hit inspect click on the bottom of my cavities that's going to give me the surface area
of the bottom of my cavities i'm going to multiply that times the height that's going to give me my
volume now i know that copper has a density of 8.96 grams per cubic centimeter so from there i
can figure out what the weight of the copper that i'm putting in the crucible should be nine pounds
this is the amount of copper that i need to make the part sure seems like a lot but
numbers don't lie
This was a big pain in Buttocks
oh yeah that sucker's hot
whoa that's heavy
i don't care if it's too messy i just want it completely full
this is what i got here a little bit rough around the edges looks
pretty ugly but i think it'll finish up real nice
better than i expected
and this here is the finished part i think it came out really nice overall i do want to mention that
this isn't the first part that i showed being machined earlier in the video this is actually
the third casting i had to recast the first one because i had some separation marks in between the
first and the second pour and then the second one that i cast which came out better than the first
was damaged when i broke a drill bit in one of these holes and then i broke a tap and another
one of these holes the entire process was a nightmare three times over it's like 10 degrees
outside and i am pouring sweat the only good thing was that every time i recast it and re-machined
it it came out better and better and this is the third one and i think it looks pretty good
it's coming out pretty good so far and the way i originally designed this is to accommodate
a sheet metal enclosure that bolts on to the front of this and hides everything inside but
for now i want to see everything working inside so i'm going to get this chip mounted bolt this
to the table temporarily fire this thing up and after all this hard work see if it actually works
it's almost there but i'm going to tilt this up to let the rest of the air out and speed things up
the water block is completely full with coolant and now the final step
the moment of truth to test it the entire goal of this project is to run this chip
at full power which hasn't been done before while keeping the temperature
of the chip under 140 degrees fahrenheit around 60 degrees celsius i got everything all set up
i have my thermometer right here on the chip i got the infrared camera set up let's do it
all right here we go
25 power
50 power
75
and 100.
i see some smoke coming off the face of the water block but that might just be my wires heating up
110 degrees i'm just gonna wait for the temperature in the entire system
to equalize see what it tops out at and just to show you how bright this light
actually is i'm going to look away i'm going to put my hand in front of it check this out
that's like so bright i can't even look in my hand
it's really hard to convey on camera how bright this light is but
it's intense it looks like that's where it's going to stay about 122 degrees fahrenheit
that looks good to me i thought it was going to hit about 125 but it looks like an equalized
there it's about 70 degrees ambient temperature well it looks like my temperature didn't exceed
125 degrees that was my goal and i achieved it and this wouldn't be a finished video unless i did one
high-speed clip lighting it up with this light it's not gonna be perfect because this isn't
done but at least it'll give you an idea of the quality of light that this chip makes check it out
All these clips were viewer Requests
that was extremely satisfying that this actually worked there was a lot of iterations of this to
get to this point my main challenge here was to be able to remove the heat fast enough from the chip
into the actual coolant sounds really simple but it was actually very difficult to be able to get
that much heat transferred in such a small surface area this has been a nightmare taking scrap copper
and turning it into a finished part was no easy feat the hardest part for me was casting because
copper it's not an easy metal to cast it ends up absorbing a lot of the air molecules into the
liquid copper and then what happens is when the copper solidifies that air tries to get out and it
creates aeration in the casting which is all those little air pockets that you see the only way i got
over that was by using a different technique i put a lot of flux into my crucible first heated it up
waited till the flux was melted and then added the copper so as the copper transitioned from a solid
phase into a liquid phase the flux was the barrier in between that transition and protected that
molten metal from the air all the way up until the pot was full then i poured it and i got a clean
casting which i was very surprised because those were large parts that's all i got for you in this
one hopefully you enjoyed that episode i hope it was inspiring or at least entertaining but
tell me what you think in the comments below and look out for some future episodes where i
use this light adios
oh that was only the top sort of off
i don't know what happened there
i completely cut the top off and i'm definitely not eating that piece because
yeah it's kind of well i guess i could wash it off two one oh i got that one i finally got a useful
christmas present so let me open up these knives and see if they're any good so let me open up
these knives and see if they're any good kamikoto say honolulu oh no japan japan i had japan
mumbo jumbo
definitely cut my finger like this one the best