After a bit of fiddling around with the prototype and my LED tester i ran few A/B comparisons.
The thought of replacing the lens with a reflector gets more and more appealing.
A lot of light is lost as spill to the sides and the lens can not focus it.
I ran a few rough experiments with a bit of aluminium and press-form tools out of the 3D printer.
Something like this should not be done in one go but i got a few results, even these crappy "reflectors" produce more light output then the lens.
I will have to put more thought into this approach, but it seems like a good idea.
In other news, the tests with PETG have been put on hold for two reasons.
One is, that i have more important things to focus on, the other is this:
Over extrusion, layer separation, blobs, zits, stringing, oozing, you name it.
At least for me it is not the ultimate PLA replacement, at some point i will have to tackle this again but not for now.