Background

Around 40 million Americans go camping every year, and they use headlamps in order to see in the dark with their hands free. However, headlamps require batteries and bulbs which are expensive and bulky, and often need to be replaced. Now that almost everyone in the US owns a smartphone with a flashlight, this lightweight and adjustable phone headlamp will make it easier and cheaper for people to partake in activities in the dark.

Comparison

Phone Headlamp

• Adjustable for any phone size
• No need for batteries (just need a charged phone)
• Can be used to film things from first perspective
• ​Parts are easily replaceable

Standard Flashlight or Headlamp

• Hand held and inconvenient
• ​Expensive parts
• Bulky
• Batteries and bulbs need to be replaced

Materials, Design, and Manufacturing Summary

• Plywood for laser cutting
  • Quick, cheap, flat, easy to use
• Nuts/bolts for easy adjustment
• Foam for ergonomic design
• Rubber strap for adjustability

• ABS for 3D printing with Ultimaker 2+
• Quick, cheap, allows complex geometries
• PLA for 3D printing with Type A 3D printer
• Quick, cheap, allows complex geometries​

Prototype in action!

Acknowledgments

This was a fun group project for an introduction to manufacturing and tolerancing course. The other students that assisted with this project were Bianca Champenois, Cameron Stearn, Jack Wang, Owen Farmer, and Paul Dennig.