Mining Cap Lamp Headband Bracket
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Two (2) styles of headband brackets to use your miners lamp without a hard hat.
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These headband brackets allow you to clip a mining headlamp onto a headband for use around the house / etc. Based on the same measurements as the MSA 15244 hard hat bracket. I'm using an NLT Polaris cap lamp.
Design Notes:
- Slotted for a 1" wide headband strap:
- I took the strap off a cheap Energizer headlamp I wasn't using.
- You can use a feed-through headband, or a one-piece band that cannot be separated, by notching the straps in the center (refer to below).
- The positioning of the strap slots, the bracket, and the overall size of the headband plate was tested to get the best balance/center-of-gravity, and security when moving around.
- I opted for the bigger overall “forehead plate” to help secure the weight of the mining cap lamp. I found smaller plates tended to wiggle around and meant the strap needed to be uncomfortably tight. The bigger plate lets you use a looser strap.
- There are two (2) models: an all-in-one bracket, and a two-piece that allows you to adjust the up/down position of the lamp (for balance), or you could use the bracket to mount to something else entirely.
- I recommend using the simple all-in-one bracket, unless your lamp is very different than mine.
Printing Instructions:
- PLA or PETG worked fine for me.
- I suggest using a brim just in case. My PLA prints worked ok without, whereas the PETG pulled up a bit without the brim.
- Observe the orientation of the parts, the “all-in-one” headband and individual lamp bracket must be printed with the rectangular slot down. For the “all-in-one” headband, “support on build-plate” should be used.
(Optional) Notching the Strap Slots:
If you're using a one-piece headband that cannot be separated (like an Energizer headlamp strap), cut notches into the middle of the slot to insert the strap:
(Optional) Using the Lamp Bracket:
Nut pockets and mounting holes/slots for the individual lamp bracket are for M3 hardware. The slotted headband uses M3 countersunk screws. Mounting holes are 32mm center-to-center, if you want to mount the bracket to something else.
- If you find the up/down lamp angle of the “all-in-one” headband doesn't work for you, you could modify the bracket to include an up/down angle that works for your situation.
Other Customization Notes:
- I've included the Fusion 360 archive (.f3d) file so you can modify the design for your needs. The timeline is a bit messy but you should be able to tweak the design or check measurements (eg: forehead curvature, strap width).