4-LED 2-AA Flashlight

thingiverse

Create your personalized LED flashlight by printing it out! (Note: Electronics and batteries are not included.) For further details, check jtfdailycheck.blogspot.com. Warning: The initial setup I used caused a short that destroyed the batteries and melted the wire insulation; make sure your connections are properly insulated. All components can be printed without support. My printer isn't precise, yet the parts fit perfectly. Solidworks files for modification are included. Assemble as follows: 1) Glue a wire within the ribs of the main body using hot glue, leaving two-inch excess on both ends. 2) Solder a wire to one terminal of a button placed in the back cap. 3) Solder and glue a spring to the backside of the button, plus a nut on the other side for better contact with the battery terminal. 4) Glue and solder LEDs (in parallel) on the cone, ensuring accessible anode and cathode terminals. 5) Attach wire to one LED terminal; the negative battery terminal should be at the back with the switch. 6) Secure the other LED lead between nut-glued hot glue and create a contact point for the battery using metal or similar. 7) Cut out an acrylic circle of about 50mm diameter for protection. Enjoy! Update: I modified the switch mechanism by using a bolt and spring, with the bolt making contact with the back of the battery. This modification requires no special parts but may be less reliable; however, it's less likely to short. Feel free to experiment with wiring setups!