led torch in TPU

thingiverse

I needed a waterproof LED flashlight using a lithium coin-cell that could be printed from TPU. Several good designs were available on Thingiverse, but they weren't designed for TPU as far as I could tell. So I decided to create one myself to eliminate overhangs. My printer struggled with overhangs in TPU, so I needed to design a new one. A bright LED (5mm diameter) and a 3v lithium cell are required. A CR2032 battery works well. To assemble the flashlight, print the ledTorch piece twice - these are the case halves. The LED goes through small holes that need to be poked through with the legs. After printing, I snipped these holes into narrow slots to make it easier to put things together. Identify the LED anode and cathode by testing them with the cell first so you get the battery in the right position. Trim the legs with a side-cutter or similar tool. The washer goes on the negative side of the battery to keep the cathode leg of the LED away from the battery until the case is squeezed. You can test it all before sealing the case. I joined the two halves of the case using a 200-degree soldering iron. Flexible superglue might work too, or even the inflexible stuff - just make sure it's between the battery and a leg. This design doesn't need a raft or support, and in fact trying to use supports made it look ugly. That's why it has this 'no-overhangs' sort of design that it does.