Rechargeable Flashlight from HFT Work Light Parts

I made a rechargeable work light, dual rechargeable light and had parts left over so I made my own design light from leftovers. I have pictured most of the things needed to do this. five printed pieces. From blue light used items: 3 LED strips, push button switch, rubber switch button, three resistors from board - 10 ohm. 18650 lithium cell (I scavenged mine from old drill pack). Small gage hookup wire 20 to 24 gage. Four 3mm x 4 or 6mm screws. Micro USB charging board, One HiLetgo 5V 1A 18650 Lithium Battery Charging Board TP4056, bought 10 pc at Amazon for $7.79. (Dec 2022) Amazon.com: HiLetgo 10pcs 5V 1A 18650 Lithium Battery Charging Board TP4056 Lithium Battery Charging Board Micro USB Charge Module With Protect : Electronics

Top Assembly:

One picture shows where the 10 ohm resistor is located. One used for each 3 LED strip. One alternate is to strap all 3 sets of LEDs together and use a 30 ohm resistor off of one of the sets. The picture of the black LED frame is a partial print. The outer edge can be a 1mm or two above the flat surface. This can be an alignment holder while soldering the assembly together to prevent accidentally touching and melting the full light top part. The boards will need to be sanded or cut to fit inside the frame. Look carefully at my orientation of the boards. The boards have three sets of LEDs soldered plus solder tabs between two of them. Use those to keep the iron heat from the LEDs. The blue wires cross from board to board with the negative black wire lead out. Solder the three resistors to each board and the other ends solder together with a positive wire coming out. Hold battery to wires to make sure all LEDs light. Press boards down firmly and hot glue all boards and wires down, Set aside.

Body Assembly:

Solder everything outside the case. Negative hookups: Wire long enough from bottom of cell to top of body case soldered to bottom of battery. The other end to B- on the board. Tip: Due to close fitting in the case, solder to the board with all wires at least straight up or leaning toward the USB plugin. Solder LED top negative wire to - out on board. Positive hookups: Positive wire about 2 inches to B+ (Don't solder to battery yet). 1 to 1 ½ positive wire to + out on board, the other end to single pole of switch or strapped across double pole. Solder LED top positive wire to other side of switch. Switch tabs will need to be clipped or bent back for plastic keeper will slide past. Touch last wire to battery and press switch for proper working. Two reasons for not soldering last wire. Easier to assemble and solder last, and I don't like pushing everything together live. 

Final Assembly:

Board: tight fit, pictured, the angle to wiggle the board in to the bottom area, when all the way down the USB will slide slightly into the slot and allow the board to set down flat. Drip hot glue onto the back side of the board and hold down until secured. Insert rubber button into hole, slide square hole keeper in forward slot, V side in first, it will stop against board. Insert switch into alignment square with LED wire up. Slide rectangular switch keeper into slot all the way. Slide battery in with wire going into slot. Stuff excess wire also into slot. Now solder final wire to top of battery. Place thin battery insulator over battery and put in two 3mm x 4 or 6mm long screws. Test again. Align top and bottom together while stuffing wires inside top cavity. Pieces should snap into place. insert a screw on each side. Note: The tabs are probably the flimsiest part of the case. I stripped out one side. If this happens open back up and push some hot glue in the tab hole. Snap together and as the glue is setting up quickly put the screw in again. When charging the case will glow at the area around the board.

• Designed with Tinkercad
• Printed on Creality Ender 3
• EZT red PLA filament from Amazon
• 25% infill
• 0.15 layer
• used no supports

2/19/2023: I added Flashlight Mag Body.stl. Modified body to add two 8mm x 3mm neodymium magnets. Untested for fit.