I really like this Rechargeable 650 Lumen Keychain flashlight (https://www.amazon.com/dp/B08HYQ5FYQ). It's super bright!

But it would keep turning on in my pocket, leaving it dead when I needed it. So I designed this switch cover for it.

The TPU is flexible enough that I can press the switch through it, but sturdy enough that the light doesn't come on in my pocket.

Bambu Lab

Bambu X1C

No

No

16mm

35

The flashlight originally had a metal clip, and it "sort of" covered the switch. But then to get to the switch, I would have to remove the clip and set it somewhere. I almost lost it many, many times, and then finally one day couldn't find where I'd left it.

Because it was a clip, I made a clip. I used calipers to measure, and came up with a clip, which I printed in PLA. The first iteration broke almost immediately in my pocket. So I strengthened it and tried again. That was better, but the PLA stretched after a few days, and it wouldn't stay on.

I talked to some folks at work, and they helped me realize that I didn't need to make a clip: I wanted a switch cover! So I closed the ring, and printed with TPU.

It's a tight fit, but it slips on from the back of the flashlight, and covers the switch quite nicely. The flexibility of the TPU lets me access the switch without moving the cover, while still protecting from random presses.

I've been using it for about a month now, so it may be a little early to declare victory, but it hasn't degraded at all, so I'm feeling pretty good about it!