Printable Headlamp for Caving/Mining

thingiverse

Printable rugged headlamp includes lamp housing, helmet mount, and battery pack. Update 2-24-2018: Added pdf files - exploded views of the headlamp and battery pack assemblies, as well as a heatsink detail. Minor updates to parts list. More updates coming soon! Update 7-1-2015: Added new housing with recessed hinge; added beefier helmet mount; added individual .stls and new complete build file. Instructions Print parameters: Material - ABS Layer thickness - .2 Infill percentage - 100% Shells - 3 Raft status - No!!! Print directly to build plate! Supports - Yes Print time on my Rep 2x: 4h23m I have added "drawn in" rafts and supports so that you can print directly to the build plate. Remove supports, clean up parts, use a twist drill to clean out holes. I highly recommend doing an acetone vapor bath on all of the parts before assembling. This will strengthen and help seal out water and moisture, plus it gives it a nice glossy finish! If you don't understand what the parts are on the list, you may not want to attempt this build!!! PARTS LIST: 3 1 watt star mounted LEDs - Cree XPG2s or newer 3 20mm compatible optics - Carlco 3 20mm optic holders - Carlco 1 driver board - TaskLED HBFlex 1 1/2" barrel, panel mount style push button switch - preferably IP67 rated - APEM 1 switch boot - if applicable - APEM 1 standard 3mm Red LED - for battery status indicator(if driver board has option) 1 aluminium heatsink - diameter 50.8mm, thickness 1.6mm 1 2-conductor power cable - approximately 5mm diameter 1 connector for headlamp cable 2 connectors for battery and charger cables 2 PG7 plastic cable glands 1 4-40 x 1 Socket Head Cap Screw 18-8 Stainless 1 4-40 Nylon Insert Lock Nut 18-8 Stainless 3 4-40 x 3/16 Socket Head Cap Screws 2 4-40 x 3/4 Socket Head Cap Screws 1 4-40 x 1/4" Socket Head Cap Screws 13 #2 X 1/4 Pan Head Screws 18-8 Stainless Steel 4 Binding Posts, 13/64 Barrel Dia, 1/8" Barrel Length Stainless Steel 1 O-ring - 2"ID X 2 1/8"OD X 1/16"CS 1 54mm x 1.68mm acrylic lens 1 7.4 volt Li-Ion battery pack(2 x 18650 cells) Other Items: conformal coating 2-part epoxy solder acetone di-electric grease heatshrink tubing silicone