Energizer Headlamp HD5L33AE Strap Mount

thingiverse

A couple of years ago, I bought an Energizer headlamp, specifically the HD5L33AE model. At some point, the plastic piece that holds the strap into the headlamp broke, causing the lamp to no longer stay on the band. I messaged Energizer about a replacement part and was told they don't keep parts, but they offered to send me a coupon for a certain amount off the purchase of another headlamp. Not exactly my idea of a solution, but they were nice enough to put the coupon in the mail. Since I'm not one to toss out a perfectly good item, this is one of the first things I've worked on with my new 3D printer. This replacement part doesn't have the sleek lines of the original part, but it fits my lamp perfectly and even matches up with the ratcheting piece on the lamp. I printed mine with a shell thickness of 1.2mm, .2 layers, and 50% infill. I also set the bridging/support type to Everywhere. Then, I ran this through Cura. Once printed, it took me a couple of minutes to clean out the bridging and smooth the edges. There are pictures of this printed part and also on the lamp with the strap back in place. My first version had to be modified because I increased the hole diameter for the small pegs on the lamp and added a couple of mm around the peg holes for extra strength. On my first attempt, the holes were so close in diameter that one side split. I attribute this to the size of the holes and also to printing with only 20% infill. That's why I went up on the infill in my second attempt, added a couple mm more around the peg holes, and increased the peg hole diameter to 2.1mm. They fit perfectly now. One last thing, I will probably put some foam or moleskin on the back where it touches your head for comfort. Also pictured is the original mount that broke. The second picture shows which headlamp this is. Not sure if this will fit others; I measured the distance between the pegs as 59mm to help. Everything was designed in FreeCAD 1.6 and exported to STL. Print Settings: * Printer: MonoPrice Maker Select V2 * Rafts: No * Supports: Yes * Resolution: .2 * Infill: 50% * Notes: Printed in PLA; I used 1.2mm edges for added strength.