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Author 3D printing a head lamp / battery pack
Joanne

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3D printing a head lamp / battery pack
Posted: 30/04/2015 18:58:26
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So the Oldham headlamps are becoming scarce and repurposing other lights to act as headlamp shells is hit and miss, any thoughts to 3D printing? I can see some question about whether they would be sturdy enough. Certainly they wouldn't provide ideal thermal conductivity, unless you could print using 3D mental printing which is starting to become available.

On the positive side one could design any size or shape that is desired. Round, square, oval, or even triangular could be easily produced. Battery packs for any type and quantity of batteries would be a straight forward task.

Here's a link to a guy who is currently building lamp shells using a 3D printer.
http://www.thingiverse.com/thing:537222

A friend of mine is putting together a 3D printer so I may explore this option. I shot some video underground this past weekend using the flood mode on my Speedy Special as the primary light. Now I would like to try to make a couple of video lights that would run on 18650 battery packs and mount to the video rig.

Thoughts? Pros / Cons?

Joanne
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Mr Mike

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3D printing a head lamp / battery pack
Posted: 30/04/2015 21:00:33
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I've 3D printed some prototype parts for my work, including a battery box for 3x18650 cells.

I think for your own use and most definitely for quick prototypes it is fantastic. But without a lot of fiddly post finishing, a far cry from a finished commercial product, unless you like the rough look.

Like the guy says on the link, the raw product will not be waterproof, so you need to do a acetone vapor run on it, which basically dissolves and fuses the outside layer.

Here's my attempt



(click image to open full size image in new window)



(click image to open full size image in new window)



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Mr Mike www.mineexplorer.org.uk
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ChrisJC

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3D printing a head lamp / battery pack
Posted: 30/04/2015 22:16:21
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Also be aware that 3D printing is not like 2D printing. It might be in 10 years time, but it's a far cry from 'design, print'.

It can take an age of trial and error (and design tweaks) to get what you want.

Chris.
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Joanne

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3D printing a head lamp / battery pack
Posted: 01/05/2015 04:05:28
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All good points. Although it doesn't sound ready for prime time, it still seems like a useful tool for the one-off lights like I am looking for. And of course out here in the desert, it's more important for our lights to be dust proof rather than water proof. :-)

Joanne
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royfellows

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3D printing a head lamp / battery pack
Posted: 01/05/2015 08:03:38
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I struggle to see how something can be waterproof but not dust proof?
I seek enlightenment



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He told me 'I seem to eat batteries”. No wonder he has a bad stomach.
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sinker

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3D printing a head lamp / battery pack
Posted: 01/05/2015 09:14:54
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I think the point was that it could be dust proof but not necessarily water proof. A well fitting cover/lid would be dustproof but would not need the waterproof treatment to the finished surface.....?


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gNick

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3D printing a head lamp / battery pack
Posted: 01/05/2015 09:33:10
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Or on a commercial basis, not need immersion testing with attendant cost.

I like the way you can have something rated to IP57 that allows limited dust ingress but can be immersed in water up to 1m deep.



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Give a man a fire and he will be warm for a day. Set a man on fire and he will be warm for the rest of his life.
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royfellows

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3D printing a head lamp / battery pack
Posted: 01/05/2015 10:55:58
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gNick wrote:

Or on a commercial basis, not need immersion testing with attendant cost.

I like the way you can have something rated to IP57 that allows limited dust ingress but can be immersed in water up to 1m deep.



Is that the definition of it?
Laugh

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Blober

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3D printing a head lamp / battery pack
Posted: 01/05/2015 11:29:42
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10 years away?
Mmm, I think its a lot closer than you think.

https://www.youtube.com/watch?v=UpH1zhUQY0c

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FILTH
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Mr Mike

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3D printing a head lamp / battery pack
Posted: 01/05/2015 11:32:58
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I read about the Carbon 3D in a journal last month, pretty impressive for speed. Apparently inspired by the Terminator and the liquid metal robots.

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gNick

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3D printing a head lamp / battery pack
Posted: 01/05/2015 12:24:17
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royfellows wrote:

gNick wrote:

Or on a commercial basis, not need immersion testing with attendant cost.

I like the way you can have something rated to IP57 that allows limited dust ingress but can be immersed in water up to 1m deep.



Is that the definition of it?
Laugh

Pretty much - that's the spec of a lot of the motors we use on a pipelay tower.

Heading back to 3D printing, the metal stuff is impressive but the cost means ordinary mortals are probably better off sticking to machining from solid...

--

Give a man a fire and he will be warm for a day. Set a man on fire and he will be warm for the rest of his life.
IP: 195.12.27.234 Edited: 01/05/2015 12:26:57 by gNick
Wormster

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3D printing a head lamp / battery pack
Posted: 01/05/2015 17:02:41
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Hmmm this has got me thinking.

Blackshed labs here we come - I might be a while on this one!

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ChrisJC

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3D printing a head lamp / battery pack
Posted: 02/05/2015 09:24:18
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Blober wrote:

10 years away?
Mmm, I think its a lot closer than you think.

https://www.youtube.com/watch?v=UpH1zhUQY0c


Do you want a bet on when you'll be able to actually buy one?

I bet 10 years.

Chris.

P.S. I have a 3D printer right next to me, and I can vouch for the fact that we are in the middle of the 'Peak of Inflated Expectations', heading rapidly for the 'Trough of Disillusionment'.
http://en.wikipedia.org/wiki/Hype_cycle
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royfellows

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3D printing a head lamp / battery pack
Posted: 02/05/2015 10:40:44
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ChrisJC wrote:



I can vouch for the fact that we are in the middle of the 'Peak of Inflated Expectations', heading rapidly for the 'Trough of Disillusionment'.
http://en.wikipedia.org/wiki/Hype_cycle


Mars Bar prize of the day!
LaughLaughLaugh

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He told me 'I seem to eat batteries”. No wonder he has a bad stomach.
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Tony Blair

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3D printing a head lamp / battery pack
Posted: 02/05/2015 12:55:36
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I like the link. Very good.

I wonder if the hype surrounding 3d printing is perhaps to the detriment of other, capable methods. I've looked at the oldham body and contemplated it's construction and replication. I would be looking at shed-moulding.

It would be interesting to know what Oldham did with their tooling if they have killed the old caplamp. Indeed, what sort of tooling it was an how many impressions you could get made per press.

An old company of mine had a disasterous dally with injection moulding and lost a fortune, however, I am utterly convinced of it's capability to produce a fine product at relatively low scales. Thinking of the design of the oldham, you would need a 3 part tooling, rather than a 2 part. This would complicate things somewhat. I presume the bezels also need to be unscrewed from the tooling, which would be a hot hands experience....I don't imagine oldham were a big enough company to muck about with a line which did this automatically.

I think the future is firmly in the scurion direction, both in materials, finish and performance...which will be trailing somewhere behind RF. Laugh
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royfellows

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3D printing a head lamp / battery pack
Posted: 02/05/2015 13:05:06
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Tony Blair wrote:



I think the future is firmly in the scurion direction, both in materials, finish and performance...which will be trailing somewhere behind RF. Laugh


Way off thread and very sorry but your offhand comment about the "crispness" of the Scurrion output made me think. I am now looking seriously at light quality as well as quantity.

Moving this to my thread shortly

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He told me 'I seem to eat batteries”. No wonder he has a bad stomach.
IP: 92.19.55.213
royfellows

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3D printing a head lamp / battery pack
Posted: 02/05/2015 20:02:33
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Sensible question, hopefully
Just how strong are items created by this process as opposed to the conventional?

I think plastic headsets have no use now except for working mines where an absence of aluminium is necessary to meet safety certification, but I am thinking about battery cases.

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He told me 'I seem to eat batteries”. No wonder he has a bad stomach.
IP: 92.19.55.213
ChrisJC

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3D printing a head lamp / battery pack
Posted: 02/05/2015 22:06:35
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I think they are perfectly fine. I have never seen a 3D print of this type physically failing.

Chris.
IP: 109.148.185.191
Joanne

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3D printing a head lamp / battery pack
Posted: 03/05/2015 03:48:12
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Hey Roy,

I was thinking the other way around, dust proof but not necessarily water proof. With the exception of my jaunt over to England, all my exploring is in quite dry conditions.

As Mr Mike pointed out, the state of 3D printing does not appear to be up to commercial standards. My original idea that it might be useful to create small batch production lights is probably invalid. On the other hand it would be adequate for my needs of creating a small video light. On the other hand, some web surfing might produce a housing that could be adapted to my needs.

Joanne
IP: 70.173.16.49 Edited: 03/05/2015 03:49:51 by Joanne
Wormster

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3D printing a head lamp / battery pack
Posted: 03/05/2015 08:11:06
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Joanne, is there a local "Hack Space"? they usually have all the kit, all you need is the drawing files and some $$ for materials.

That link you posted has got me thinking, I really like the battery box design, it would fit my Bodgelight's with a bit of modification, I'm going to be investigating further with No1 son, as he's got the right kit to print, just have ti figure out this acetone vapor bath jobbie!

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