Summary

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 .2
Infill 100%
Shells 3
Raft 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 you assemble. 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 oring - 2"ID X 2 1/8"OD X 1/16"CS
1 54mm x 1.68mm acrylic lense
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

Printable Headlamp for Caving/Mining