BRAUN 500 Lumen Work Light Headlamp Conversion Clip

This clip is specifically designed to securely hold the lamp on your head, making it even more versatile for mechanics, DIY enthusiasts, and anyone who needs reliable lighting on the go.

Key Features

Design: The clip's center of gravity has been calculated to ensure a balanced fit that won’t tip forward or side. The button remains easily accessible without interference.

Strong and Secure Fit: The clip uses plastic deformation to hold the lamp firmly in place. Even vigorous movements, like a headbang, won’t dislodge it. No wobbles, no slips.

Adjustable Lighting Angle: The lamp can rotate within the clip for precise light placement.

Bonus Strap Mount: The project includes a file for an elastic strap mount base, inspired by the design of an affordable headlamp from Harbor Freight. For the best experience, I recommend purchasing the original headlamp (often available for $1–2 or free during promotions), removing its cheap light, and using its straps with this clip for a professional setup.

With this clip, your BRAUN Work Light becomes a 3-in-1 tool: a stationary lamp, a handheld flashlight, and now a robust headlamp.

Included Files

STL file for the clip.

STL file for the base for elastic strap mount.
 

Print Recommendations
Print the clip vertically!

Material: PLA+ is recommended with standard settings, but PETG and ABS will also work.

Layer Height: 0.2 mm.

Infill: 20–30% (Grid or Gyroid).

Supports: Generate supports only for the overhanging section with the screw hole.

Nozzle Size: 0.4 mm.

Printing Temperature:

PLA: 200°C (nozzle) / 60°C (bed).

PETG: 240°C (nozzle) / 70°C (bed).


Assembly and Usage

• Print the clip and strap mount (if needed).
• Purchase an affordable headlamp from Harbor Freight, remove its light, and replace it with this clip using the same mounting hardware.
• Alternatively, print both the clip and the strap mount, attach elastic straps to the mount, and secure the clip to the mount using a screw and nut.
• Insert the BRAUN Work Light into the clip.
• Wear the setup on your head and adjust the light angle as needed.
  
  
  Future Plans

If this project gains popularity, I’m considering expanding the design to include:

A version compatible with GoPro mounts.

Adaptations for other headlamp systems or strap standards.


Licensing

Creative Commons – Attribution (CC BY). Feel free to remix and improve, but credit the original creator!