Starlight Device - Night Vision Aperture Modification Device and Cap by cloud9actual

Last crawled date: 3 years, 4 months ago

Synopsis (TL;DR - skip this):
The Problem:
Users of night vision devices typically do not have the ability to adjust the depth of field of the intensified image and thus have to constantly adjust the manual focus to view subjects near or far. Additionally users who own these expensive devices want to protect the image intensifier tubes inside the devices from being damaged from excess light when turned on.
The Solution:
This mechanical device enables the user of night vision devices to select a desired aperture thus controlling the depth of field and allowing the user to focus on a wider range of subject distances. This device also allows the user to close off all light entering the system for safe storage and peace of mind when transporting the devices. This system finally allows the user to flip the device out of the way to enable normal, unimpeded use of their night vision device.
How it's different than other devices:
Currently, night vision users can purchase either a standard lens cap or lens cover to protect the system from intrusions or light. They can also purchase aperture modification devices. However, a system that allows for aperture adjustment, unimpeded use of the night vision, and complete light and foreign object ingress protection does not exist. Additionally other devices are complex and expensive while this device is designed to be inexpensive and easy to use in dark conditions by providing haptic responses.
Other systems only allow for one or two types of function. Either the user can employ a system to adjust aperture and protect the lens from ingress but those systems cannot prevent light ingress, or they can employ a system that prevents light ingress but cannot adjust aperture.
The devices currently on the market are both expensive and limited. The users of them have to remove aperture adjustment devices to employ a lens-cap to prevent light ingress and vice-versa. Additionally these devices are expensive and carrying multiple types of devices is undesirable in an outdoor environment at night. These devices also do not employ a tactile response and require the user to look at the system to adjust the aperture.
This system enables the user to select a desirable aperture, close off the system from external debris and light, and disable the system completely by flipping it to the side but it still stays attached for quick re-employment. This device also employs a tactile response so the user can feel each selection.
The Nitty Gritty:
I have designed this "Starlight Device" in order to have a better system to adjust the depth of field or focal range on my night vision devices. Unfortunately the solutions currently on the market are very cost prohibitive and lack certain features that I desired. These features I wanted were the following:
The ability to select between multiple aperture sizes in the field
100% self contained (no spare parts to keep track of)
Has tactile settings for each aperture size
Uses minimal components
Lightweight
Durable
Inexpensive
The only features that are to be added in future versions are a sacrificial lens and a tie down point. I am currently working on adding these features.
The system was built around the Butler Creek 09A Multi-Flex scope cover since it already has the flexible, well fit cup to fit around the ocular lens, and it contains the hinge and spring parts.
Here is a list of the 3D printed components:
Cap Body
Aperture Ring
NOTE: I recommend printing the cap and aperture ring in the default position which should be the outside surface facing up and enabling supports only touching the buildplate.
Here is a list of all the non-printed parts used in this design:
M2 x 0.4 mm flat head screw, 4mm long
an AR15 takedown pin detent and spring (cut the spring down to the desired length for optimal resistance on the aperture ring)
Butler Creek 09A Multi-Flex (UPC 051525209096)
The installation is fairly simple but tedious.
First, you disassemble the 09A scope cover by removing the hinge pin and pulling the cap off. You don't have to remove the hinge pin completely, but just enough to allow the cap to be removed. I recommend pushing the pin out with a small screwdriver or correctly sized punch.
NOTE: be careful when you pull the cap away to not lose the spring! This is needed later so keep track of it. If you lose it you'll have to buy another cap.
Next, you'll assemble the printed Starlight Device components:
Test fit the detent and spring in the hole that runs along the width of the cap body. You'll need to cut the spring down to about 2/5 of the length and insert the short cutoff into the hole. Be sure when cutting to not mangle the spring too badly or it won't compress/decompress. Once the spring is cut and placed in the hole, place the detent into the hole. It should stay put with gravity and careful handling.
Now you'll insert the aperture ring into the opening where it obviously belongs and while inserting it, make sure to press the detent into the hole so that it stays compressed once inserted. Be careful to keep the aperture ring from falling out or the spring will throw that little pin out into the abyss, never to be recovered. ;)
Lastly, while holding the aperture ring in place, you'll affix it using the M2x4mm flat head screw from the inside of the cap. The aperture ring has a threaded hole to accept the screw. Depending on your printer this hole might be a little snug, but as long as it positively thread in you should be fine. For extra security you can use some thread lock on the screw, but be sure it doesn't get anywhere else because it will cause issues with spinning the aperture ring.
Tighten the screw so that its snug but not too tight because it will inhibit the rotation of the aperture ring.
Right now the aperture sizes are the following:
9.525mm
5.56mm (based on the recommendation from Slade from GBRS GROUP)
3.95mm
No light/blank
I recommend using ABS or Nylon for this part and preferably in a dark color that has the lowest light transmissivity possible. PLA + also works but is susceptible to warping in hot environments so I don't recommend it for serious use. I did design this part to be machinable so you could theoretically machine these from polymer or even metal but that would be heavy and dumb.
It's not too hard to put these together with a little time and effort. Hopefully this is useful to those who are makers and want to save a few bucks on this type of device. If you wanna support my development efforts any donation is appreciated and I'm also going to be selling these assembled.
I seriously considered patenting this design, however, as a maker/engineer I always like to be able to make things myself and I figured some of y'all might feel this way as well. So here it is! If you don't wanna go through the trouble of making these then just message me and I can hook you up with an assembled Starlight Device.
With this in mind, if you have an idea for an improvement or want to see another feature, comment below and I'll do my best to add the feature.
Stay frosty!