Very much what I'm thinking, though we haven't seen a need for reflectors, here's what I proposed on the GHSC google group.
BTW if anyone is interested in tracking the Hacker Space Challenge details join the group. [email protected] I'm enamored of the idea of pouring little ice-cube trays full of 10x LEDs. I was thinking of just cutting a set of negatives in foam, but I think would be a bad choice to get them to release etc.
My latest thought is to carve a little forest of them in foam or mdf, then get flexible silicone mold making stuff, and pour it over the forest (which we cleverly leave a lip all the way around). So then we have a silicone ice cube tray thingy to pour something clear, maybe Easy Cast or the like in, prop the LEDs on little rods so the are at the right depth and let them set.
My biggest concern is attaching the giant wires to the little LED leads in a discrete way, tough to hide when it's all clear.
Well that and I found a very loose Z-axis lead nut, and no proper wrenches to fix it today.
So what are everyone's thoughts?
http://www.iasco-tesco.com/ has silicone stuff, and EasyCast we can get at Michael's etc