This is the detailed instructions for a case study with the library: the 3D-Printed LED Flashlight
- 3D Printer; right now I've only done thorough testing on MakerBot Replicator
- Needle point tweezers (helpful in wrapping and inserting components)
- Small scissors (helpful in trimming excess thread)
Bill of Materials
(4) 5mm LEDs, you'd probably prefer white
(2) AAA batteries
(2) conductive threads ~12in each
(2) conductive threads ~18in each
Printed Bill of Materials
: (all with default settings, no raft, no support)
(1) electronics top
(1) electronics bottom
(1) flashlight tube casing
(1) flashlight cap
(1) toggle switch piece
(11) end cap
: Make sure you test your LEDs, with about the 3v from the batteries. It also might be a good idea to test the batteries...
: Referring to the schematic attached, there are 4 traces to run. Detailed instructions for how to wrap the individual components can be found in step 3.
1. Start on the back, the "electronics bottom" board with the two batteries. Orienting the LED slots to be up, run your first trace (~18in) between the positive end of the left battery and the negative end of the right battery (top left to bottom right). Insert end caps.
2. Also on the back, wrap the second trace (~12in) from the positive end of the right battery, around the peg that is behind the LEDs, but in front of the batteries. Place the "electronics top" on the underside against the "electronics bottom", with the LED holders pointing in the same direction. Feed your excess thread from the peg through both holes at the peg's base, so that it emerges on the other side. Flipping the two boards over, wrap the rest of this thread around the corresponding peg next to the hole.
3. Starting on the back again, with the same LED up orientation, start the third trace (~18in) on the upper left peg. After a few wraps, have your thread emerge from the top, to run across in front of the LEDs, and do the same wrapping on the upper right peg. Have your thread again emerge from the top, and feed it through the hole nearby. Flipping the electronics over, wrap the two upper most LED pegs in the same fashion: solid wraps around each peg, and running across in front
of the LEDs. Once all 4 are wired, you should still have decent excess thread. Run your trace down to the peg below, and across the switch. Finish wrapping that peg, and insert a peg cap.
4. Lastly, your last trace (~12in) will be the rest of the switch attached to the battery. Start by tying the knot around the switch, as is explained in step 3. Insert the toggle switch (should snap into place), and move it to the on position
, or you won't have enough slack to operate the flashlight. Run the thread down to the peg at the base, and give it a few wraps. Then feed the thread through the hole at the bottom right
, so it will emerge in the right place. Flipping the electronics over, there is one remaining battery terminal. Wrap your excess thread around this, the negative end of the left battery. Insert peg cap.
5. Insert the components
. In this case, there are 4 LEDs and two batteries to insert. In this case, I suggest inserting the batteries first, and wrap with the switch on. This way, you'll know quickly whether or not you are inserting the LEDs correctly... For both the top and the bottom, there are two LEDs to insert. Orient them such that the positive leads (the longer one) run down to the peg in the center, and the negative leads out to the pegs on the side. You will need to bend the leads a little to fit properly, but be careful not to bend them too much because they are prone to breaking. Once they are all in place and working, insert the final peg caps, anywhere there was a loose thread or a component lead.
6. Put it all together
. Slide the combined electronics piece into the tube, such that the switch is exposed in the cut-away. The cap then fits onto the front, and twists into place.
Congratulations, you have now printed your own flashlight!