3D Printing

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

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.