The first step to building the Uber-light 1000 is to print or at least start printing all the components. I used OpenSCAD to draft the parts and attached both my .stl files and .scad files so you can easily make changes/revisions. You can print the parts in any order you like, but I recommend following the order below so you can work on other steps while the larger components are printing. The 3D printer I am using is a Prusa Mendel with a standard non-heated bed topped with masking tape. I used my standard typical settings and only activate/deactivated the feature "raft" (http://wiki.bitsfrombytes.com/index.php/Skeinforge_Raft
). For each of the components I list whether or not I used "raft" and the reasons. Naturally, different printing configurations may require different settings.
2. LED Cap
Reason: Sometimes the raft will peel off the first couple of layers in the print.. This piece has fairly strict tolerances (don't want LED lens to be too loose or too tight).. so I leave the raft off. Sometimes the ends curl up, but they push back flat when fastening to the heat sink.
5. Body End Segment
Reason: Reduces the "mushrooming" of the bottom of the print. Without raft, you are likely to have a ridge at the end segment to end cap splice.