Title: Upcycled 18650 Rechargeable Flashlight Mod (TP4056)

About the Project This project breathes new life into a standard headlamp. Instead of throwing it away or constantly buying disposable batteries, I designed this custom enclosure to convert it into a robust, rechargeable handheld flashlight using an 18650 lithium-ion battery and a TP4056 charging module. It's a highly practical upcycling project!

Bill of Materials (BOM)

• 1x Standard LED Headlamp module (80mm / 8cm diameter)
• 1x 18650 Lithium-Ion Battery
• 1x TP4056 Charging Module (Type-C)
• Basic wires and soldering tools

Print Settings & Materials

• Materials: Yellow parts are printed in PLA. Brown parts are printed in ABS for better heat resistance and durability.
• Special Setting: "Fuzzy Skin" (outside walls only) is enabled to give the flashlight a rugged, tool-like texture and better grip.
• Infill: 20% (Increase to 30%+ if you want a more rugged, heavy-duty feel)
• Supports: Yes (Supports are required for printing the enclosure properly)
• Wall Loops: 3 or 4 for extra structural strength

Basic Assembly Instructions

1. Disassemble the original headlamp and extract the main LED housing and switch.
2. Solder the 18650 battery to the B+ and B- pads on the TP4056 module.
3. Solder the LED wires to the OUT+ and OUT- pads on the TP4056.
4. Carefully place the components into the 3D printed enclosure. Ensure the Type-C port aligns perfectly with the charging cutout.
5. The battery is designed to be press-fitted (squeezed) tightly into its slot inside the enclosure. You don't need any extra screws or glue for the battery.

Happy printing and upcycling!