Project: Designing my own cavelamp - Worklog and discussion

Hi,

Welcome to my cavelamp project!

In 2018 I descided to design and create my own headlamp for use in mine and cave exploration.
My old headlamp had a tendency to run out of battery fast, overheat and it lacked important safety functions for underground use.

I started searching for good alternatives designed for my use, but all I could find was expensive products.
With my background and experience in electrical engineering I thought for myself: I can make my own headlamp, just the way I want it to be.

During 2018 I desinged and made the headlamp I wanted. I even made 10 units for me and my friends. Why only make one right?

What I will show you now is the finished product, and in the future mabye the second revision/version.

Feel free to drop a comment if you like what you see, or if you have any questions.

Features:

- Up to 1200 lumens on HIGH

- Emergency light (up to 50 lumen) for low power use, or for power saving

- UV light (left reflector)

- RGB (right refelctor)

- Battery monitoring and 5x battery LEDs

- Standby LED (this will give up to 10 lumens for many days, even for weeks)

- Battery protection

  • Waterproof design


Finished housings and PCB test fited


Finished product. Got my name on the PCB


Side view


All black exteriour, blue PCB design


GoPro mount


All 10 headlamps I made

Hugely impressive project. Are you making more and selling them, or was this a personal project? If the cover is just polycarbonate, does it block the UV? What power source are you using?

All of the PCBs are customized, names and symbols :o
Nice work!
BTW, how’s the layer beneath the PCB, for heatsinking?

Good work! :+1:

Very impressive and professional looking. Any thoughts on making more? There’s a market for a decent budget caving lamp.

WOW!

Very cool! They look great even when turned off!

Share some pics of them being used underground. :+1:

Nice!

Thanks for all the comments!

Thanks, might make a new batch this winter or next year. Will post info on my Instagram if I make units to sell (Instagram in bio).
The UV light shines through the front acrylic glass. Could have a kind of filter on it, but it works nice without.
Using 18650 batteries in parrallel at 3,7v

Thanks!
On the underside of the PCB I have the drivers soldered on the PCB. The light sources are placed on the housing itself for cooling

Might make a batch this winter or next year. Will make a post on my Instagram if I make units for sale (Instagram in bio)

Thanks, here is a few photos from our lates caving trip:

Wow , great project!

I’m a caver too.For caving without diving I prefer to use unibody headlamp they are small , lightweight,durable, ease to change battery and has enough light and runtime to work during one day.

Added a short video showing a test of the headlamps:

very cool!I want one :heart_eyes: