3D Printed Parts

Parts are designed to be 3D printed with FDM based machines. STL files are oriented to print "as is". Machines with dual extrusion or single extrusion setups are listed below with parts name and description. Parts require tight tolerances that might need adjusting slice setting. Reference the suggested settings below.

Clips for Bike Frame

The headlight and box enclosure are designed to clamp onto the bike framing. There's a lot of different types of bikes, each with different sizes of framing. Take a moment to measure your bikes framing to ensure the clips will fit.

  • Box clips: 38mm (1.5 inches) diameter
  • Headlight clips: 23mm (0.9inches) diameter.

Dry Fit Parts

I suggest testing out the parts before installing the electronics. Print out the clips and try fitting them onto your bike frame. Fit the bhl-box-clip.stl parts onto the railing of the box enclosure – If the tolerances are too tight, use a filing tool to loosen up the edges. Fit the bhl-cover-jst.stl and bhl-cover-usb.stl parts onto the box enclosure.

Tap Mounting Holes

I used a set of screw taps to create threads in the various mounting holes. This greatly improves fastening screws. of the A mix of metric sizes are used here. M2.5 tap for the Feather mounting plate. M3 tap for the majority of the mounting holes.

Slice Settings

Use these settings as reference. Values listed were used in Ultimaker's CURA 3.X slicing software.

  • 0.2mm Layer Height / 0.4mm nozzle
  • 0.38mm Line Width (inner & outer widths)
  • 60mm/s printing speed
  • 20% infill

Dual Extruded Headlight

The headlight was designed to be dual extruded using black and translucent PLA filament. When backlit, any geometry printed in translucent filament will illuminate and diffuse the lighting from the NeoPixels. If your 3D printer is not equipped with a dual extruder, you can 3D print the part in translucent PLA and mask certain areas with black acrylic paint.

Dual Extruded Box Enclosure

One side of the box features "grill" details that are printed in a silver colored filament. This is purely for aesthetics and does serve any functionality (other than testing your dual extrusion setup!). You have the option to print a "single" extrusion version.


Mounting plate houses NeoPixel Ring and NeoPixel Jewel.


Clips attach to mounting plate and bike framing.


Headlight diffuser – Ideally print in a dark colored filament.


Headlight diffuser – Ideally printed in translucent colored filament.


Enclosure houses electronics.


Grill details on the side of the box enclosure.


Box enclosure for single extrusion.


Headlight diffuser setup for single extrusion.

Glitter Infused Filament from Fillamentum

The material used to print the some of the parts in this project are from Fillamentum. From the PLA Extrafill line of filaments, Vertigo Galaxy PLA and  Rapunzel Silver PLA was used. Translucent PLA material was used to print the bhl-headlight-b.stl part.

This guide was first published on Nov 06, 2018. It was last updated on Mar 08, 2024.

This page (3D Printing) was last updated on Mar 08, 2024.

Text editor powered by tinymce.