Lamp

I wanted a small, cordless, low profile lamp for the coffee or dinner table for when I feast or have to do work while watching entertainment in an otherwise dim room. Instead of purchasing one, I decided it would be easier and cheaper to buy individual components and make one (sarcasm).

-1 IP2368 USB-C fast charging module

-1 LM2596 DC-DC Buck Converter

-1 18650 BMS Lithium Battery Balance Protection Board

-4 18650 Batteries

-1 Embedded Touch Dimmer

-12V, 2-pin LED Strip

-1 Piece of hollow steel rod found in the dumpster during move-out time

-Black PETG filament

-JST connectors

-Wire and solder

I used SolidWorks to design the parts.

From bottom to top there are:

-4 Feet

-Bottom Plate

Consists of ventilation holes and slots for stack effect cooling, feet mounting, and battery clip mounting, and vertical posts to mount higher parts to. Snugly holds LM2596 DC-DC Buck Converter.

-8 Battery Clips (only two depicted in assembly)

Printed separately with different orientation so that layer lines would not compromise bending strength. "Welded" into place with filament and soldering iron.

-Upper Plate

Hole pattern for airflow. Snugly holds IP2368 USB-C fast charging module and 18650 BMS Lithium Battery Balance Protection Board. M2 hex socket screws secure this plate to the lower plate's posts.

-Case Top

Covers all. Secures to bottom plate with M4 hex socket screws. Holes in top for touch dimmer and steel rod. Hole on side flat face for USB-C charging.

-Rod base

Connects steel rod to case top. "Welded" to case top. Steel rod is friction fit into place.

-Shade

Friction fit onto top of rod. Has ventilation holes for cooling and for wires to LED.

Once the feet and battery clips were welded onto the lower plate, the circuit boards and battery cells were slid into place, and the upper and lower board were screwed together.

The four batteries were connected in series for a final potential of ~14.8V. The IP2368 was soldered to the batteries and the balancer, then to the LM2596 Buck Converter, then the touch dimmer.

The connected case top and rod base were placed over, and secured to the assembly with four counterbore screws.

A wire ran through the metal rod, which connected the dimmer output to the LEDs, which were adhered to the inside of the shade.