The initial gobo design was inspired by the Sea-wing Theater logo and my old design for the PGHS logo. By combining these two elements, I was able to produce a satisfactory rough draft of the design using spline tools in a Fusion 360 sketch. Future iterations of the design were only modified slightly in order to strengthen supports in the design.

In a brief testing of various materials, I experimented with 3D print PLA, aluminum, wood, and multiple film plastics. The tests made me realize the serious constraints involved with this project. The gobo needed to be small, a maximum diameter if 23.7 mm. Additionally, the material could not exceed 1 mm in thickness. Tests involving 3D prints were largely unsuccessful due to lack of necessary precision from the 3D printers. Additionally, using the Tormach 24R to cut the design into aluminum was also unsuccessful. Even using precise engraving bits, the machine still proved to be too powerful for the thin material and complex design. 

Subsequent testing on the LS-1420 CO2 Laser Cutter indicated that thin film plastics would be more successful in producing the gobo while remaining within the 1mm thickness constraint. Among these, Mylar was the most successful. The material was almost paper thin while still being strong enough to maintain its shape under the heat of the laser cutter. Mylar also produced the first successful iteration of the smaller gobo, allowing me to begin testing with the spotlight.

Unfortunately, Spotlight testing yielded many challenging results. The heat of the LED spotlight deformed the Mylar prototypes instantly upon placement before the light. This development presented a dilemma for the development process. I had to find an extremely thin material that was heat resistant enough to oppose the LED heat, but still possible to laser cut. This criteria led me to a vinyl-based material originally intended for baking.

Note: Large amount of heat produced by an LED light is generally unusual but is characteristic for bright spotlights.