My fully custom 18650 Flashlight prototype with a 3D printed body.

19 posts / 0 new
Last post
PeterF
Offline
Last seen: 2 years 8 months ago
Joined: 06/25/2016 - 14:28
Posts: 113
Location: Germany
My fully custom 18650 Flashlight prototype with a 3D printed body.

For the past few months i have been working on this and i finally got some documentation and the prototype done.
This is a completely scratch designed flashlight that is powered by 18650 cells from old notebook battery packs.
It uses a fully custom circuit to drive the LED and manage the battery.

Fully 3D printed main body.
Dimmable in 31 steps, no PWM.
Rechargeable with a regular phone charger.
Uses a single 18650 Lihium Ion cell.
Battery level Indicator.
Three button interface.
Arduino IDE compatible microcontroller.
Full battery management and protection.

Light output: 197 Lumen.
Color temperature: 5000K
Color rendering index: 83
Efficiency at 100mA: 159 Lumen per Watt
Efficiency at 250mA: 119 Lumen per Watt
Runtime: TBD

Height: 110mm
Width: 45mm
Depth: 26mm
Weight: 130g (with battery)

Here is the full documentation including a ton of pictures:
https://hackaday.io/project/21001-brightenmacher

dekozn
Offline
Last seen: 2 months 4 days ago
Joined: 06/17/2016 - 09:04
Posts: 785
Location: Be

dude Thumbs Up looking great. I was gonna ask bout heat transfer but prob. not much heat generated….

Idiot proofing something only creates improved idiots.

PeterF
Offline
Last seen: 2 years 8 months ago
Joined: 06/25/2016 - 14:28
Posts: 113
Location: Germany

Thanks!
Heat was the biggest problem, the final version will have a temp sensor on the LED and my goal is still to upgrade it to two LEDs instead of one.
It runs up to about 75°C with two LEDs, which is too much for the used plastic.
But, while heat was a problem, it is not a great concern anymore after quite a few practical tests and measurements.

It produces around 1.5W to 3W of heat, which is quite a lot on a thing this small.

saypat
saypat's picture
Offline
Last seen: 38 min 36 sec ago
Joined: 07/13/2011 - 20:32
Posts: 3579
Location: Calif

order form?

THE_dAY
Offline
Last seen: 3 days 12 hours ago
Joined: 05/18/2013 - 12:56
Posts: 467
Location: sfv, california

Very nice, the three button interface looks promising, the top button to raise brightness and bottom button to lower brightness?

PeterF
Offline
Last seen: 2 years 8 months ago
Joined: 06/25/2016 - 14:28
Posts: 113
Location: Germany
saypat wrote:
order form?

It is just a for fun project but i am thinking about a limited Kickstarter, Gofundme or other type of funding run.
Unless someone in china steals my idea beforehand and starts churning them out by the buttload Smile

THE_dAY wrote:
Very nice, the three button interface looks promising, the top button to raise brightness and bottom button to lower brightness?

At the moment, yes.
But since the light is programmable the buttons can take any task i want.
It only has one hardwired function, the light can only be turned on by the middle button.

The processor will only wake up from the power down state if triggered by one external pin, the one the middle button is wired to.
But after that the button can take on any other function.

Rufusbduck
Rufusbduck's picture
Offline
Last seen: 6 months 4 days ago
Joined: 04/04/2012 - 15:34
Posts: 10389
Location: Golden state

I’m thinking this would come under machine made category if you did one for the next contest. Really amazing effort how you persevered.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

The Miller
The Miller's picture
Offline
Last seen: 1 year 11 months ago
Joined: 12/14/2015 - 12:08
Posts: 9908
Location: Charente France

very nice
I bet if you share the files for printing more will make it, it looks great!

PeterF
Offline
Last seen: 2 years 8 months ago
Joined: 06/25/2016 - 14:28
Posts: 113
Location: Germany
The Miller wrote:
very nice I bet if you share the files for printing more will make it, it looks great!

Thanks!

Already uploaded them, the STLs are linked in the sidebar:
http://www.thingiverse.com/thing:2233707

The thing still has a bunch of bugs to be worked out though.

Rufusbduck wrote:
I’m thinking this would come under machine made category if you did one for the next contest. Really amazing effort how you persevered.

Thanks!
It tried to break my spirit more then once Smile

Contest? What contest do you mean? ;^^

The Miller
The Miller's picture
Offline
Last seen: 1 year 11 months ago
Joined: 12/14/2015 - 12:08
Posts: 9908
Location: Charente France

OL build from scratch contest
Indeed interesting where 3D printing would fit, I agree with RBD, machining!

CRX
CRX's picture
Offline
Last seen: 6 months 1 day ago
Joined: 04/02/2013 - 15:27
Posts: 4231
Location: Scotland

Nice work, interesting Thumbs Up

alphazeta
alphazeta's picture
Offline
Last seen: 2 years 6 months ago
Joined: 11/03/2013 - 11:50
Posts: 541
Location: NYC

Very polished work. Thx for sharing. Thumbs Up

PeterF
Offline
Last seen: 2 years 8 months ago
Joined: 06/25/2016 - 14:28
Posts: 113
Location: Germany
The Miller wrote:
OL build from scratch contest Indeed interesting where 3D printing would fit, I agree with RBD, machining!

Thanks, found it!
I will try to look out for the next one, although since I put everything together on another website, it kinda disqualifies me for the entry Smile

CRX wrote:
Nice work, interesting Thumbs Up

Thank you!

teacher
teacher's picture
Offline
Last seen: 2 years 2 months ago
Joined: 02/23/2016 - 19:04
Posts: 9596
Location: NE & SW Alabama

Excellent! It turmed out very nice…. Smile

You never know how a horse will pull until you hook him up to a heavy load./"Bear" Bryant 

 .................................. "Slow is Smooth, Smooth is Fast" ...................................

       Texas Lumens Flashlights / M4D M4X Deals : sign up - save $$$$  

         Rudeness Level _ mΩ _ {width:70%} _ LightWiki _ LED Tint Chart  

      Xlamp size chart _ BatteryU _ Flashaholic? Need Professional Help???            TheOriginal _ TAB _ LightSearch _ BatterySearch _ 14500's _ DiCal 

 

                                             

Phlogiston
Phlogiston's picture
Offline
Last seen: 3 weeks 2 days ago
Joined: 10/27/2016 - 16:57
Posts: 988
Location: Scotland

This is very cool.

It’s good to see you succeed after all the ups and downs you had during the design process Beer

Random thought: that not-quite-smooth 3D printed finish looks like it would be nice and grippy Smile

Rufusbduck
Rufusbduck's picture
Offline
Last seen: 6 months 4 days ago
Joined: 04/04/2012 - 15:34
Posts: 10389
Location: Golden state

This light wouldn’t qualify for the next contest but you could start a new one when the next contest comes around.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

PeterF
Offline
Last seen: 2 years 8 months ago
Joined: 06/25/2016 - 14:28
Posts: 113
Location: Germany
teacher wrote:
Excellent! It turmed out very nice…. Smile
Phlogiston wrote:
This is very cool. Random thought: that not-quite-smooth 3D printed finish looks like it would be nice and grippy Smile

Thanks!
Yes, the texture of the thing is very much a design feature and not a manufacturing artifact.
But to be honest, initially i wanted to sand and smooth it.
Until i realized that the texture is slip resistant, it fits the whole idea rather nicely i think.

Rufusbduck wrote:
This light wouldn’t qualify for the next contest but you could start a new one when the next contest comes around.

The next one is currently printing, there will at least be another two versions i think, this is far from over Smile

MRsDNF
MRsDNF's picture
Offline
Last seen: 2 months 1 week ago
Joined: 12/22/2011 - 21:18
Posts: 13473
Location: A light beam away from the missus in the land of Aus.

Its good to see your light finished. That is one fine piece of engineering. Thumbs Up

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

PeterF
Offline
Last seen: 2 years 8 months ago
Joined: 06/25/2016 - 14:28
Posts: 113
Location: Germany
MRsDNF wrote:
Its good to see your light finished. That is one fine piece of engineering. Thumbs Up

Thanks!
Just wait a few more weeks for the next version, just minor tweaks but i think it will work and look even cooler Smile