Aligning circular pattern with LED disc/ring

[cyangaze]

I've been trying to design a 3d printed diffuser for an LED disc and even though the squares fit the individual LEDs (each LED is 5mm x 5mm), and I have triple checked the correct number of LEDs, the circular pattern just doesn't align when I make it in the sketch. Well, maybe 4 LEDs line up, but then you see progressively the square covers go out of alignment with the LEDs.

This is a reference photo I am using. The view is not perfectly orthograpic, but a good representation. I used the dimensions in the photo:

Here is a screenshot of the model:

I have also attached the Fusion file

[davebYYPCU]

LEDs (each LED is 5mm x 5mm)

Why are your squares 7 mm?
Make one square on each ring, pattern the model block, not the sketch.

Might help….

[cyangaze]

Thanks! I made the 7mm for thickness of the shell and tolerance to cover the LEDs. So try a circular patter of a body rather than sketch?

[davebYYPCU]

Sketch patterns are not recommended, when modelling patterns will work.

I don’t understand why you think 7x7 blocks would be the same as 5x5.

Might help….

[cyangaze]

The blocks (3d printed) 7x7 are not the same as the 5x5 LEDs, they just have to be bigger than 5x5 in order to cover the 5x5 LEDs. But the issue isn't that, it's that the covers of the LEDs don't align. I did try modelling bodies, however it produces the same result unfortunately.

[laughingcreek]

when I line your canvas up with the body it looks pretty good. can you mark up where it's not aligning?

[cyangaze]

Thanks, I've attached an image showing where it's aligned and misaligned.

[billbedford]

There are 241 LED marked on your canvas, and 249 7mm cubes on your model. 

[Warmingup1953 · Accepted solution]

It would be great to have the Module in hand but I'd keep the sketch very simple:

and Circular pattern faces (or features):

[davebYYPCU]

You only need centre and first ring block in that sketch.

Rectangular pattern the 1st ring block, spacing 10mm.

[cyangaze]

That worked! Also turned out the diameter was 172mm, so I adjusted your sketch, but yes that definitely worked, thanks!