Coleman Headlamp Battery Cap

thingiverse

I have a couple of year old Coleman LED headlamp that still works well despite being two years old. However, the cap for the battery finally gave out and I can no longer get the light to turn on without the cap in place. Unfortunately, buying a new one isn't an option anymore because the repair pieces are not available anywhere. To solve this problem, I designed a replacement part that fits perfectly. **CAUTION**: This is an experimental design that has not been thoroughly tested yet. My plan is to print it with high-impact resin using an SLA printer. However, I may also try printing it in solid form with ABS plastic on a Zortrax 3D printer. This replacement part was created with Tinkercad and can be edited online at https://www.tinkercad.com/things/l8adsyPl8MW. UPDATE - I've successfully printed the design on a MakerBot Replicator 2 using PLA material. It requires some sanding and cleanup from the supports, but it fits perfectly in place. The print is a bit tighter than the original cap, but it still works great. To my surprise, the print didn't separate along the z-axis shear lines as I had expected.