Final project

Fab bike headlight

The fab bike light kit is an open-source dynamo powered bycicle light system with integrated batteries that allows to charge devices while commuting.

The Fab bike light kit comprises of 3 main elements.

Voltage Regulated [5v] Bicycle Dynamo Light and USB Charger
diy-bicycle-dynamo-usb-charger-for-smartphones-and-battery-packs

I will give the kit a vintage style and will be embedded with modern tecnology.

dinamo dinamo

I will use he a 6v-3w front wheel shimano dinamo as the power source and I want to integrate 18650 Li-on cells from old computer packs. The front light will host most of the components.

List of components:

front light
led beam
on/off switch< br> mini usb connector
battery pack
charge controler module
head light casing
backlight casing
front wheel dynamo
charged/uncharged led indicator

Development phases and schedule:

1- research and define the tecnical specifications of each electronic components (bateries, charge controler, leds, switch)
2- design those components according to system specifications
3- design the casings so they respond to tecinical specifications and desired aesthetics for the device.

Front light

The front s the most complex element to design because it will host most of the components ( the lamp, the on/off switch, the battery, the charge/uncharge led pilot, the USB miniconnector.

Thefirst model of the front light was created in Rhino, making a paraboloid shape using curves, sweep commands and meshes.

custom box rhino

I will have do some more tweaking with the design but anyways this model shall serve as a base to define the inner component placement.

The cap of the front light was also created in Rhino, and the Gcode was generated with Cura to generate. There are still lots of details to be figured out. The biggest challenge is to make the plastic translucid and as clear as possible for the light to pass through.

Here the original vintage part I use as inspiration and a render of the base model I now will develop.