Milwaukee Hard Hat Headlamp to Work Light

PLEASE SEE IMPORTANT NOTES IN THE “REQUIRED HARDWARE” SECTION BEFORE DECIDING TO PRINT THIS

This is to allow you to use a Milwaukee Hard Hat Headlamp (Part #2163-21) as a work light that can be held or stuck somewhere with a magnet. Cutouts for magnets are included on both the bottom of the handle, and the back of the main housing.

Printing Instructions

I have included a .3mf for Bambu Studio if you have a Bambu printer and you want to print it in PETG. Otherwise, use the following information to create your own profile:

Print all objects in the supplied orientation in the STL files.
Handle - Supports touching build plate only so that the magnet cutout is supported but the upper threads are not.
Main Housing and clips - Regular Supports
Handle Nut - No supports
I printed most parts with high infill and walls, specifically 6 walls and 40 percent gyroid infill. The exception is the main housing where I brought the walls down to 3.
Optional but it looks good - I printed the main housing with fuzzy skin (contour with fuzzy skin point distance set to 0.2mm). If you do this I also recommend using the Bambu Lab textured PEI build surface as the pattern that it puts on the bottom surface blends in nicely with the textured walls.
I also used the Arachne wall generator instead of classic, but I don't think this is particularly important.
Also note that I printed everything in black PETG, although I was thinking it'd look pretty cool to make the housing red to match the Milwaukee colors a bit better. I've included a render so you can see what that would look like. You could also maybe do a red handle and a black housing.

Required Hardware

2 * M3 cap screws (about 10mm is optimal I think, but I think the ones I used were 12 or 13 mm and a bit of extra length isn't going to hurt)

2 * Neodymium disc magnets (3mm thick). They must be pretty strong.

Please note that while I normally like to post things after they're 100 percent finished, in this case this I'm posting something that is more like 98 percent there. The issue I had with this is that I ordered some disc magnets from Amazon that were supposed to be 32mm in diameter. The actual diameter when they arrived was closer to 29.5mm, so I adjusted the cutouts for the model to be 30mm, and that's what they're at in the provided files. The other issue is that they were supposed to be very strong magnets (N52 I believe) and they were nowhere NEAR as strong as advertised, and so they were barely adequate. These are what I used: https://a.co/d/9QUCieq 

If you want to build this model using different magnets, measure your magnets and send me the measurements on MakerWorld and I will happily adjust the model to work with them in exchange for knowing exactly what you used so that I can recommend them to others. I do check my messages there pretty much daily. (You can also message me here on Printables as I am also here quite often)