I did have another swing at it. The first one I’d hoped to slip intact around a stiffer carrier. This one I made wider, and corrugated, so it printed better.
The slat based collimators are such a pain, I've decided to go for it and try making lenses instead. I think a 3D printed mould will be good enough - the layer height is very much smaller than the LED size, and a bit of scattering is actually desirable. I'm printing this vertically so the lens profile gets the high resolution. It's going to be precarious when it reaches the top.
I had to turn the print 90 degrees - it wiggles rapidly doing the lens profiles, and when that was on the bed slinging axis it shook the whole room. It's a lot less dramatic when it's just moving the head.
It’s very unbalanced with only one collimator attached, so I’m spinning it too slowly for persistence of vision. But I’m sort of able to convince myself I’m seeing depth. There’s a lot of mechanical stuff I need to do before I can start cranking it up.
The black filament is surprisingly shiny. My first attempt turned out to be a light pipe, and didn't restrict the view. In this version, the slats have a zigzag profile.
This is the current approach for reducing the horizontal field of view of the screens - a big heavy box o' slats. I'd like to make a lenticular array, but that's a whole side quest.