Micro LED Lamp

thingiverse

Hi there, This is a fun little project that lets you upcycle some old batteries and learn more about using FreeCAD. Today we're going to create a small micro LED lamp using parts I found when cleaning up. Requirements: 3 Batteries LR41 (other possibilities are noted below) 1 LED 1 Improvised switch made from metal, wire, or folded aluminum foil Tools: 3D Printer Pliers (optional but recommended) Requirement Notes: I used metal from an old file for documents. After cutting it to length, it fit perfectly. When using a wire, make sure the ends have proper contact. A single-core wire works best due to its spring effect on the switch. Using folded aluminum foil may not give the best results. Adding some paper to fold around can add more spring effect. You may need to decrease the battery compartment's "roof" to gain enough space for your chosen switch design. However, you can easily rasp it down without printing a new part. Printing: This project is tiny, and supports may cause trouble. The small gaps between the battery compartment are required. The one in the back is to get the metal part through, while the first one allows you to pop out the batteries and fit the LED. I printed it upside down, but you can print it in any direction you like. This project doesn't require a lot of plastic, so you'll learn about your printer's capabilities too. Due to fragile components, it's wise to print at high quality. Again, this part barely needs any plastic. Make sure your printer is calibrated, or you may get a part that's too small or too big. Assembly: Assembly is the hard part since there's no battery cover. I designed the lamp to be a tight fit. Prepare the LED first by placing it onto the ledge of the printed part where it will be mounted. Cut the wire without the goblet so it hits the case. Now bend the one with the goblet 90 degrees inwards and cut it as shown in the pictures. Insert the bended LED wire using the gap under the "roof" of the battery compartment. If done right, the LED holds itself, and the small ledge of the printed part will fit perfectly between the LEDs wires. Now insert the batteries with the plus side facing the LED. Make sure the first battery hits the LED wire with the front side. Along with the last battery, put the metal part or wire into place and bend the other side to just not connect to the other LED wire. You may need pliers to push the batteries in place. Trust me; they will jump around a few times until everything is in place, but once you're finished, everything is rock solid. If done correctly, you just need to push the metal, wire, aluminum, and the LED lights up. If the spring effect is big enough, the "switch" should open the circuit when you stop pushing it. Notes: Even though this project is only for LR41 batteries, you can change the sketch of the LED lamp to fit any other battery at your disposal. Since I'm still a beginner with FreeCAD, the included file may have some issues. Please don't blame me; this project exists to learn how to design parts and create functional items as a reward for myself. Happy Printing!