LED Rechargeable Flashlight (V2)

thingiverse

Here is the rewritten text with minimal editing for clarity and readability: **3D Printed LED Flashlight Assembly Instructions** This guide will walk you through the assembly of a homemade 3D printed LED flashlight. Please follow these steps carefully to ensure successful assembly. **Step 1: Prepare Battery Holder Piece** Clean and prepare the battery holder piece by eliminating any support or print bumps in the groove. **Step 2: Solder Leads to Battery Terminals** Solder a 5-inch lead to the negative side of the battery, fitting it into the groove on the battery holder. Use thin wires (24 AWG solid) for this wire. This wire will go to one side of the switch. **Step 3: Connect Positive Wire to Switch** Solder a short flexible length of wire to the positive battery terminal. Place the battery and charger into the battery holder piece, guiding the negative wire out the bottom and the positive wire through the end. **Step 4: Epoxy Charge Board to Battery Holder** Epoxy the charge board to the battery holder such that the charger port is flush with the end of the flat plate. Use the same batch of epoxy to ensure the board stays separated from the battery. Clamp lightly in place while adhesive cures. Glue the battery in place if desired. **Step 5: Solder LED Driver Module** Solder the positive wire sticking out of the end of the battery holder part to the center plate on the back side of the LED Driver module. Trim the LED Driver module to fit, making sure it is totally round. **Step 6: Connect LED Driver to Battery Holder** Push the LED Driver into the end of the Battery Holder, ensuring connections are not broken. The LED Driver Board should be flush with the rim of the end. **Step 7: Desolder Leads from LED Driver** De-solder the leads from the LED Driver, noting which side was positive and negative. Bend the tips of the leads and hook them through the notches on the CREE LED, soldering them to the LED. **Step 8: Attach Copper Heat Sink** Using provided adhesive patches, attach the copper heat sink as square and center as possible on the back of the LED. This is important for ensuring the LED is straight. Use break lines on the top and bottom as alignment tools. **Step 9: Assemble LED Holder** Make sure the heat sink fits into the LED holder part and leads are only sticking out a short amount before gluing it in place. Epoxy the inside of the four support pillars to the corner pins. **Step 10: Attach Lens** Epoxy the lens into the LED holder, ensuring it is clean to your liking. The lens will not be removable. **Step 11: Test Polarity** Test the polarity of the LED and LED Driver by touching the switch wires together and carefully setting the two leads of the LED to where the wires were originally soldered. If no light, try reversing polarity. **Step 12: Solder LED Leads to Switch** Solder the LED leads to the switch, twisting the wires slightly so that the LED Holder and Battery Holder come together (don't glue yet). Continue testing connections by touching the switch wires together. **Step 13: Epoxy Switch in Place** Epoxy the switch in place, ensuring the locking button is depressed (off). Solder the switch leads to it, as polarity doesn't matter for mechanical switches. Continue testing the light but don't leave it on for more than a short moment. **Step 14: Assemble Shell Part** Make sure the shell part is clear of debris inside. Test fitting before electrical assembly is recommended. **Step 15: Epoxy LED Holder to Battery Holder** Epoxy the LED holder part to the battery holder part and quickly insert the entire core assembly into the shell part, pressing it all into place. **Step 16: Secure Button** Epoxy the edge of the bottom of the flexible button to the flat spots exposed to the button hole. Congratulations! You now have a homemade 3D printed LED flashlight. Please note that the light should not be used on high setting for more than 0.25 seconds, as this can burn out the LED. I hope you enjoy your new flashlight and find it useful. If you have any suggestions or improvements, please let me know in the comments below. I'm working on a bike light using an external portable battery pack, so stay tuned!