Mount for standard LED flashlights

Please scroll to the bottom of the post for update information.

The Challenge: I needed targeted spotlighting and shaped lighting for tabletop, macro, and shadow shots—without purchasing additional dedicated photo or video lighting equipment—and instead wanted to use the LED flashlights I already owned. In this specific case, I am using several LEDlenser MT14 LED flashlights equipped with focusing lenses.

I designed the mount and light discs presented here for an LEDlenser MT14 LED flashlight (1000 lumens and focus lens) using FreeCAD and printed them in PLA on a QIDI Plus 4 3D printer.

In the first version shown here, 1/4" and 3/8" UNC mounting threads are printed directly into the base (though I always finish the threads using the appropriate tap and die). Unfortunately, only after printing did I realize I had forgotten something important: the ARRI pin holes. ☹ I have already included these in a second version but haven't printed it yet (images are also uploaded).

As is standard with other photographic equipment, adapters for tool-free mounting can be attached (ARCA-SWISS, NATO/Picatinny, KB Mini Lock, etc.).

If a specific tool-free mounting system is already being used across your photo and video gear, the corresponding mount can be printed directly into the light holder. Examples include the Kondor Blue Mini Lock Quick Release System (KB-ML) https://kondorblue.com/products/new-mini-quick-release-plate, the Mini Lock QR Swivel Tilt Monitor Mount with ARRI Pin (KB-PM-MQR) https://kondorblue.com/collections/accessories/products/monitor-swivel-mount-pan-tilt, the Arca-Swiss system, the NATO/Picatinny system, or the ISO 518 cold/hot shoe system.

Furthermore, the inner diameter can be adjusted to fit the most common LED flashlights or specialized rechargeable LED pin-point/portrait spotlights. 

MAGlite (38 mm / 31 mm)
NiteCore (26 mm / 26,8 mm)
SmallRig Portrait Background Zoom Light (49 mm / 40 mm)
Neewer Portable Flashlight (52,0 - 53,5 mm)
Photoolex Zoom Light (52 mm)
Godox … ULANZI … etc. etc.

As a third option, I have prepared a semi-open version where the LED flashlight clips in and is additionally secured with a heavy-duty rubber band. This allows a single mount to accommodate flashlights of various diameters. This design can be further optimized so that a sort of half-shell can be used for virtually any flashlight diameter.

Here are a few basic print parameters I used for the prototype version shown:

Filament: PLA Rapido black (For outdoor use, for example, ASA-CF should be used.)
Nozzle: 0,4 mm
Layer hight: 0,2 mm
Wall loops: 4
Top shell layers: 4
Bottom shell layers: 4
Top/Bottom Pattern: Concentric
Sparse infill density: 30 %
Sparse infill pattern: Rectilinear
Speed: < 90 mm/s
Plate-Temp: 60 °C
Print-Temp: 210 °C
Support: Optional, depending on the 3D printer

The disc holder and light-shaping discs are printed in black PLA, while the color disc is printed in amber PETG. Regarding print settings, I reduced the number of walls and top/bottom layers to two. Recommendation: Since the LED flashlight head generates significant heat at full output, a heat-resistant filament (rated for >80°C) should be used.

I see the following advantages in the design variants and FDM 3D printing:

1. Rapid adaptation of the mount for different diameters and mounting scenarios via a simple, parameterizable 3D base design.
   

1. Instead of acquiring additional photo or video lighting equipment, you can use existing LED lights (taking into account the requirements of the photo or video project). The guiding principle is: use what you already have to save time and money.
   

1. Opportunity to offer print-on-demand and online 3D customization. Instead of producing and stocking large quantities of just a few diameters, a service bundle combining print-on-demand with parametric online customization can offer even greater flexibility (PRUSA <> Kondor Blue). This touches on aspects such as customer experience, customer retention, and enhancing unique selling points as a provider of photo/video equipment, among others.

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UPDATE:

NEW: A semi-open holder with rubber band clamps for three different diameters. The base diameter is 52 mm and can be reduced to 38 mm (MAGlite) and 26 mm (Nitecore) using insert adapters. The insert adapters have two nubs that fit into the UNC threaded holes to prevent slippage.
Note: I haven't printed this version yet and therefore haven't been able to perform final handling and functional tests.

NEW II: Added a flashlight holder for MAGLITE D series (38 mm body diameter). This uploaded version has got a inside diameter of 38,2 mm. Since I don't own a Maglite D-cell flashlight, I couldn't test the fit. I hope the D-cell models fit, given the 38.2 mm dimension. The flashlight body lock mounting screw thread is a M10 ISO.

NEW III: Updated MAGLITE Flashlight holder: Holder for the new generation for LED D-Cell and C-Cell flashlights added. Inner diameter for D-cell increased to 38.4 mm. Lettering and diameter specifications positioned at the base of the mount. Update LEDLENSER Flashlight holder: New holder for the LEDlenser P7R (2000 lumen) flashlight. Update of the holder for the MT14. All flashlight mounts feature a new, simpler, yet still robust design.