Electric unicycle headlight mount (Ninebot One trolley handle, Lampenhalter)

thingiverse

My electric unicycle is equipped with a unique Trolley-Handle that can be used to mount a headlight in a variety of ways. The handle itself serves as a mounting point for the light, which can be secured using its normal strap wrapped twice around the handle to reduce the needed diameter. In addition to the recommended rubber mount design, there are two alternative approaches that have been tested and proven effective. One approach uses a part with three large holes printed in black to secure the headlight, while another uses a smaller part printed in gray that is perfectly suited for the "V-SAV" type of headlight. The most elegant and durable design requires flexible TPU rubber filament to print so that the lamp can be inserted into the pocket. This design has been tested and proven to be extremely robust, with almost no chance of breaking anything. The filament used is black flexible TPU from Sainsmart, printed at 210°C with a slow speed of 25mm/sec. The headlight mount encapsulates only the lamp itself, leaving the adjustable plate on the back of the light intact. To adjust the angle, extra material can be wedged into the top or bottom of the pocket to achieve the desired tilt. The final design has been optimized for the Ninebot One's trolley handle position, with a 10-degree downwards tilt that appears to be just right. There is also an adapter available for mounting things at the rear of the unicycle, which can be found on Thingiverse. Print settings used were: Printer: Tinyboy Fabricator Rafts: No Supports: Yes Resolution: 0.2mm Infill: 35% Notes: The final version was printed with TPU rubber filament in face-down orientation, using 15% zigzag support and reaching through the central hole to support parts of the upper side of the eliptical ring. Machine parameters for Cura 2.1.2 were set as follows: Layer height: 0.2mm Shell thickness: 0.8mm Infill density: 35% Speed: 25mm/sec Temperature: 210°C Flow rate: 110% For those using a TinyBoy with Cura 2.1.2, my settings can be found on GitHub. When removing support material, the TPU rubber filament strongly sticks to itself, making it difficult to remove. However, zigzag support walls can be removed with minimal tools by applying manual force. Once one wall is torn away, the rest follow easily, leaving a rugged surface behind. A sharp pair of pliers was used to remove some nasty bits and stringing from the print.