3D Printed LED Crank Flashlight

Introduction: 3D Printed LED Crank Flashlight

About: I'm an Electrical Engineer with "engineer disease." I need to always be making, fixing or learning about something.

This instructable describes a way to quickly make a 3D printed, no battery needed flashlight you can use!

It would be a great family or school project.

Aside from a 3D printer and filament you will need 3 LEDs, a motor and some screws.

This project is a completion, wiring description and explanation of the work by plamenbg89 at https://www.thingiverse.com/thing:3197349

Step 1: Parts and Equipment Needed:

Parts List:

3 - Clear bright white 5mm LED's: Ebay or amazon $2.00 USD

1 - 28BYJ-48 Stepper Motor (5V version): Ebay or Amazon $1.50 USD

4 - screws (Pan Head, Phillips Drive, #2 Drill Point, #4-24 Thread Size, 3/8 inches Length) Amazon

3D printer filament

Tools list:

  • 3D printer
  • soldering iron
  • small phillips screwdriver
  • wire cutter and stripper
  • small file (optional)
  • hot glue gun

Step 2: 3D Printing

I used a Crealty Ender 3D Pro printer. I sliced the 4 .STL files at the same time using Cura. I used the "Standard Quality" printer settings in Cura I arranged the parts as shown so I did not need any supports.

Step 3: The Motor

This design uses a Stepper Motor as a generator. The 28BYJ-48 5V stepper motor can be driven backwards through it's gearing to generate an AC voltage. The LEDs are diodes and will only accept the current from the generator in one direction. As shown in the motor schematic, there is one common red wire connection that we will attach to all 3 LEDs. I chose the longer LED wire, the anode for the common connection. Any 3 of the other wires from the individual motor phases.can each go to the other side of each of the LEDs (the cathodes).

Step 4: Assembly

  1. Start the assembly by smoothing out the 5 wires against the motor housing so they are flat and not crossing each other.
  2. Insert the motor into the housing and attach with 2 screws. The screw holes may have to be gently cleared of some plastic.
  3. insert the 3 LEDs as shown in the housing. Make sure that all 3 long wires are at the top as shown.
  4. Bend the LED wires as shown in preparation to solder them.
  5. Solder the 2 long wires as shown.
  6. Remove the LEDs and hold them with a clip if you have that or get a friend to help hold them while you solder.
  7. Cut off the pink wire, strip the ends off the other 4 wires and solder the 4 wires as shown in the picture.
  8. Insert the 3 LEDs back into the housing and bend the 5 wires so the cover can be attached.
  9. (optional) secure the 3 LEDs with hot glue.
  10. Attach the cover with 2 screws.
  11. Attach the small barrel cylinder to the arm by pushing it on.
  12. Attach the arm to the motor shaft. You will probably have to use a small file here to widen the opening of the arm hole to get it to fit snugly on the shaft. It does not slide all the way onto the motor shaft.

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