Modular LED Flashlight by TV3master

Last crawled date: 3 years ago

Flashlight
The head is designed to fit one of these: http://www.aliexpress.com/item/Round-Aluminum-PCB-Printed-Circuit-Board-50mm-for-3-x-1W-3W-5W-LEDs/32262251814.html

I designed the head so that it quickly can be removed from the body without twisting the wires (and break them in the process), this is done so that i can quickly change the head so i can for example make another head with another color off leds, or a real lightbulb, the possibilities are endlesss...


"5mm led plate" and "head for 5mm leds" need to printed both if you want to use 5 mm leds, the led plate is made to hold 30 leds, this is done beacause:
The voltage coming in to the head is 12v, i used 3.2v as the voltage drop for white leds, so this gives me 3 leds in series and this 10 times. (this was the most i could niceley fit on the plate)
If you want to have a plate for less leds, just drop a comment down below and i will design a plate for you ;) (it only takes like 5 minutes to do that...)
The plate has a "U" on it to indicate the underside, the leds go in this side (there holes are wider at the top on this side, so the little ridges from the leds drop in nicely)

the cone is made to difuse the light and spread it, so the flashlight can be used to light a room easly
the cone just slides over the head.
the preferred color is white or yellow, but you can go print in different colors to get other colors light, if you want to go complelty crazy you can use rainbow filament and create an awesome color effect
the electronics:
2 protected li-ion cells
1 adjustable current usb mini li-ion charge circuit PCB (spdt switch behind the bottom cap is used to select wich cell gets charged
1 boost converter 2.5-60v 3A (set to 12V with a multiturn pot)
1 spdt switch for switching the light on
3 3W cree cold white leds (in series)
1 constant curren driver (2(ish)- 36v) (drives the leds at alot less that they are rated for to limit the heat)
important note it is possible that you need to resize the part (make it 10 times bigger) as my 3D software exports to stl in other units (parts from V1.5 and up don't have this problem)
changelog13/07/2015 18h29:
added 5mm led head + 5mm led plate
updated description13/07.2015 18h50 :
updated some parts to solve the scaling issue with my 3D software
updated instructions + added printer settings23/07/2015 22h44:
added the diffuser cone + pictures
updated description28/06/2016 09h57:
Updated Connector to V2.5, V1.5 broke in a fall as it was to thin, V2 was skipped as it didn't solve the issue much