If you've been looking for a great project to get kids involved and interested in electronics, look no further! Construct a simple 3D printed flash light using pretty standard electronics parts for cheap. Cost me around $4 for the printer filament and all electronics.
3D printer (Makerbot Replicator 2 used)
Solder and soldering tool
Sheet of tin foil
~15cm of 26 gauge wire
1x 1k resistor 1/4 watt
1x mini push button
3x 3V CR2032 coin batteries (could use less batteries if space is replaced by tin foil)
2x 3pin/ 2.54mm stackable female pin (2nd used to provide button support, need only 1 if using printed perf board)
1x 5mm LED (any color, I only had green)
Step 1: Printing the Parts
Attached are the .stl files for all printable components.
While printing, I used a standard quality print with a 15% fill.
Step 2: Circuit Assembly
Dimensions of the perf board are 20mm x 32mm.
The positive wire is 8cm long and the negative wire is 6.5cm long.
Using the circuit assembly pictured, solder the components into place. Remember to make sure that your diode is face the correct direction! (the flat spot on a diode indicates the cathode or negative side)
**The blue block is just a piece of plastic I found and glued to the board to provide support for the push button.
Step 3: Case Assembly
If you've completed all of the other steps before this, you should now be ready to assemble!
Using a needle nose pliers or your fingers, slide the circuit board into the slots on the inside of the case. Make sure that the stack-able female pin is pointed towards the opening.
The wires should poke out the back of the case a little. Bend the stripped section of the negative wire over the battery supports.
Next, place the batteries in on top of the the wire you just bent. I used 3 batteries just for longevity of its use. One could use 1 or 2 batteries but would have to replace the empty space on top with tin foil.
Once all batteries are in place, bend the positive wire over the top.
Place tin foil in the battery cap (to apply pressure to the wire contact) and screw the cap on.
Slide the clear light reflector into the light cover and screw those on as well.
Final step is to insert the mini push button into the stack-able female pin through the hole in the top of the case.
You now have your very own, hand built, 3D printed flash light!