SparkFun Flashlight Case - Compact 3D Printed Enclosure with Button

Description

This is a small, no-nonsense case for the SparkFun Basic Flashlight PCB.
Designed to be compact, sturdy, and easy to assemble, with a printed button that directly actuates the onboard switch.

Tolerances are intentionally snug to avoid rattling and keep everything aligned.

Material Needed

• 4× M3x3 heat-set inserts

• 4× M3x16 button-head screws

Printing Notes

• Tested with a 0.5 mm nozzle - no big issues

• Tolerances are tight but manageable on a reasonably tuned printer

• If it’s too tight for your setup:

  • Slightly scale the base and cover only

  • Avoid scaling the button, or it may not fit the switch properly

Material:

• PLA works fine

• PETG or ABS/ASA recommended for long-term durability

Assembly Instructions

1. Print all parts

2. Install the heat-set inserts

   1. There’s limited clearance under the inserts. Insert them carefully and don’t overheat or force them

3. Place the PCB into the base

   1. It must sit flush and tight, with no gaps

   2. When fully seated, it should feel snug and may almost “click” into place

4. Insert the printed button onto the switch

5. Close the case and secure it with the screws

References

• SparkFun Flashlight Kit:
  https://www.sparkfun.com/sparkfun-basic-flashlight-soldering-kit.html

• Official soldering tutorial:
  https://learn.sparkfun.com/tutorials/flashlight-kit/all