Customizable Flashlight to Headlamp Adapter

Flat Design

• Printed flat for strength and compactness
• Can be bent into a curved shape by first soaking it in hot to boiling water (temperature depends on the filament)
• If using TPU or a flexible filament, use the no cutout version (Headband Cutout to 0mm) so the headband won't fall out
• Can be made lighter or stronger by changing the thickness (3mm default)

Headband Loop

• Use any elastic webbing or something similar for headband
• Diagonal cutout allows existing headband loop, such as sweat bands, to be inserted without cutting and sewing

Flashlight Ties

• Various methods of attaching the flashlight is possible, such as zip/cable ties, strings, shock cords, velcro/hook & loop fasteners, etc.
• Hair ties are also possible, but the angle would have to be rotated 90° (see last picture)

Customization

• Most dimensions can be adjusted for custom hardware on Onshape
• Since there are far too many size combinations, the only models provided are for 1" headbands, 30° angle, small & large flashlight (⌀ ~20mm & ⌀ ~30mm), and zip tie & 1" slot
• https://cad.onshape.com/documents/656a12fe15a46318c93445dc/w/00f3a0b835a3f0994fcab038/e/e7dcfc1d4c53ae04e1d11b0b