Make a Torch / Bikelight (+ Mould)
Published 10mo. Edited 10moPublished 11 months ago. Last edit 11 months ago
Original Research Topic:
https://community.preciousplastic.com/research/torchbikelight
This compact and powerful Torch/Bikelight is designed for everyday reliability, whether you're commuting after dark, navigating trails, or using it as a handheld torch on the go. Built for durability and ease of use, it features a weather-resistant body and a secure, tool-free mount that fits most handlebars. Perfect for cyclists, campers, or anyone who needs a dependable light source, this torch is ideal for small-scale production, retail, or DIY projects.
Guides
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1-2 weeks
MediuminjectionPP
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More Information
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1
Download & Machine the Mould
In the .zip folder you will find all the files you will need to machine your own mould (Part A and Part B) in STEP format.
Please note the STEP file is in "mm".
The mould fabrication of this part is very complex, with multiple curved and drafted angles. Therefore, we wouldn't recommend attempting to machine your own mould without knowing what you are doing or seeking the advice of a professional machinist.
Additional information:
- Due to the intricacies of the design you will need a R1(mm) ball bit to achieve the precision of this design.
- The mould should be machined from Aluminium 7075 to ensure long-term durability and strength.
- We recommend the mould be anodised to achieve a better finish.
- The mould requires:
4pcs M8x80mm
8pcs M8 Washers
4pcs M8 Nuts
If you want to have the mould fabricated for you. We sell the mould on the Precious Plastic Bazar here:
https://bazar.preciousplastic.com/moulds/injection-moulds/premium-mould-24-torch-mould/
2
Bill of Materials
Here is a list of all the parts you will need to buy to have this as a functional Torch / Bikelight.
- A 3W LED Module (3-5V, Constant Current)(https://www.aliexpress.com/item/32984506965.html)
- A 12mm Waterproof locking push button (https://www.aliexpress.com/item/1005008683268470.html)
- A 22mm 45° Lens (https://www.aliexpress.com/item/1005004118671017.html)
- A USB-C Battery charging circuit (https://www.aliexpress.com/item/1005005037876729.html)
- A 13400 Battery (We have sourced ours from an old vape, but these can also be purchased online)
- 4 M2x6mm Countersink Self tapping screws (https://www.aliexpress.com/item/32809898654.html)
Optional:
-A mount for a bike (https://www.aliexpress.com/item/1005007301096377.html)
-USB-C Silicone cover (https://www.aliexpress.com/item/1005006625147969.html)
3
Inject
When injecting with this mould there are a few important things to take note:
- Since this mould is for structural use. We recommend injecting with PP, and avoid HDPE. HDPE is to soft and bends over time. PP is stronger and lasts longer.
- A warm mould is required to inject into to ensure success. Its also best to remove the item while its still hot. Due to large amount of pinch points, it will only get harder to remove as it cools down.
- Each injection uses about 34g of plastic
4
Electronics
Now is time to get all the internals soldered together, ready to put in the torch.
For this step, there are a few things you will need;
- A 3W LED Module
- A 12mm Waterproof locking push button
- A USB-C Battery charging circuit
- A 13400 Battery
- Around 180mm of 26AWG Red Wire
- Around 100mm of 26AWG Black Wire
Simply cut the wires to length and wire it up as the circuit diagram shows, and you should have a working torch!
5
Assemble
With all the components needed to build your Torch, it's time to assemble.
The torch assembly is fairly straight forward, each component has a space within the torch where it sits, and the wires get routed around the components.
The 22mm 45° lens can clip onto the LED allowing for easier assembly.
Once all the components have been fitted into the body of the torch, you can then screw the body together using the 4x M2x6mm screw.
Once thats screwed together, its done!
Now you can add the optional USB-C Cover and or attach the light to your bike!
6
And you're finished!
Now that is all wired up, you can grab yourself a bike torch mount and throw it on your bike!
The torch mount we're using here can be found here : https://www.aliexpress.com/item/1005007301096377.html
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