Project: Designing my own cavelamp - Worklog and discussion

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hans_magnus
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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

Cavelamp project - Follow me on Instagram: hans_magnus

bmengineer
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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?

Find all my reviews of flashlights and more gear at www.bmengineer.com

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

Good work! Thumbs Up

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

You can never have too many torches........just not enough darkness

Tixx
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WOW!

goshdogit
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Very cool! They look great even when turned off!

Share some pics of them being used underground. Thumbs Up

Lightbringer
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Nice!

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hans_magnus
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Thanks for all the comments!

bmengineer wrote:
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?

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

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

Good work! Thumbs Up

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

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

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)

goshdogit wrote:
Very cool! They look great even when turned off!

Share some pics of them being used underground. Thumbs Up

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

Cavelamp project - Follow me on Instagram: hans_magnus

AEDe
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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.

hans_magnus
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Added a short video showing a test of the headlamps:

Cavelamp project - Follow me on Instagram: hans_magnus