Summary
This 1000 lumen flashlight has enough power to light up an entire street yet is compact enough to fit in the palm of your hands.
Print Settings
Resolution:
variable
Infill:
variable
Notes:
In Slic3r, each part was printed using different settings to save on time.
body.stl - .3mm layer height | 100% infill rectilinear
top_ring.stl - .1mm layer height | 100% infill rectilinear
end_cap.stl - .2mm layer height | 15% infill 3d honeycomb
switch_cover.stl - .1mm layer height | 100% infill rectilinear
case.stl - .2mm layer height | 100% infill rectilinear
Post-Printing

Assembly
Parts List
The parts list for picture above.
Top Ring - top_ring.stl
Acrylic Lens - https://www.amazon.com/dp/B00YV5M7EM/ (cut to shape using dremel and bench grinder)
Bulb - https://www.amazon.com/dp/B01HB9WPAA (remove the springs)
Case - case.stl
Switch Cover - switch_cover.stl
Switch - https://www.amazon.com/dp/B00CQMG98W/
Body - body.stl
Battery - Uses a 18650 battery, I used https://www.amazon.com/dp/B00DUKCDDY
Spring - https://www.amazon.com/dp/B0085YWILC/
End Cap - end_cap.stl
TOOLS USED:
Dremel (used for cutting rough shape of lens on acrylic)
Bench Grinder (used for grinding rough acrylic lens into shape)
Hot Glue Gun (used to glue parts together)
Soldering Iron (used to solder wires)
Part 1
Part 1
Once all the parts have been assembled, solder a piece of wire onto the side of the bulb. Then place the bulb into the case.stl with the wire going through one of the openings.
Then, solder the wire to one of the contacts of the switch and fit the case.stl with the body.stl and place the switch into the designated slot. Use hot glue to secure them in place.
Part 2
Part 2
Now, solder a longer piece of wire onto the other contact of the switch. Put the wire through the bottom hole of end_cap.stl and solder it onto the spring (the spring can't be soldered on directly so a piece of copper wire was crimped to it using a small strip of tin and then soldered to make the contact secure). Then, fit the spring into the spring holding slot. Seal the hole with hot glue.
Part 3
Part 3
Fit the lens into top_ring.stl and then hot glue it onto body.stl
Part 4
Part 4
Hot glue the switch_cover.stl onto the switch.
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