A Torch from LED Light Hat

I had a LED Light Hat torch of Xcap brand, with damaged battery which had laid useless in my drawer. I thought it cold be usefull if I design a little torch with this LED light. This LED head produces difused light which could be practical to lit small objects when repaired or when I need light to make macro photograpy. 

My inspiration came from an old handheld torch with 4.5V battery, as one of the pictures shows (the red one). 

You can search for: the LED Light Hat on Aliexpress, Amazon or eBay. The original headlight has integrated charging from USB and USB connector as well. It does cut charging just over 4.2V. It does not have protection against battery discharge! Below battery voltage of 3V, the light is so weak that you know when is time to charge. The charging process is indicated with red light, when done, you will get green indication. 

I used single Lithium-ion flat shaped battery cell. You can use lithum polymer instead bellow dimensions described under BOM.txt file. In this file, the schematic diagram could be found too. Solder all wires according to the schematic diagram, using AWG24 or AWG28 wire. 

Quality lithium polymer cells may be obtained from: Hobby King. You can choose: US, EU or UK site for delivery. 

USB connector can be found on Aliexpress too. Search for: USB type A plug connector. 

Assembly instruction: 

• The battery holder and LED holder make a hinge where a bit of print filament in a length of 44 mm is inserted. 
• fit the USB connector with one or two M2.5 screws.
• Place connection wires as shown
• solder them always first on LED lamp and assemble it.
• than, cut wires and solder them on the USB connector and last on the battery. Schematic diagram can be found in BOM.txt file. 
• The cantylever is mounted onto battery holder by help of two scres M2.5x10 and washers. It may be rotated in 8 predefined positions. Combination using angled LED holder and cantylever make it possible to direct light in many ways. 

The charging regulator is integrated into this flashlight. Charging may be performed by plugging this unit directly in a USB socket, either on a Power Supply charger or desktop PC. It could be tricky to plug this device into a laptop. I have permanently connected a USB type A extension cable, which I use for charging. 

I want to point out, that this torch has nice diffuse, not concentrated hard light, excellent for lighting, of nearly placed,  small objects.

There is no need for support material during printing.