100W LED Lamp with Bosch and other Tool Batterys

thingiverse

It´s a relatively small lamp which you can power with your Bosch Power Tool batteries, you can use other battery brands too, if you make a new backplate for it. It´s mostly built with old and cheap parts from amazon and an old PC. The LED is cooled with an old cpu cooler with a 80mm fan from asus. The LED is just screwed on the heatsink with wood screws and toothpaste as thermalpaste. Then I used a DC to DC step up, also screwed to the heatsink but at the back, to power the LED. Behind the heat sink with the step up and LED, is the 80mm fan from the Asus CPU cooler. It´s powered by a DC-DC step down, and then fed through a fan controler, which turns on the fan if the heatsink reaches a certain temperature. There is also a switch and a board with a relais, which cuts the power to the step up and LED, when the battery voltage becomes too low. The contacts in the backplate are just some flat connectors glued into the holes with superglue. You have to assemble the LED, heatsink and step up first, then put it in the case. Behind that comes the fan with a fanguard behind and in front of it. Then, there is not so much space left, in there you put the fan controler, step down for the fan, and if you have it, the undervoltage protection board. Glue the switch in the left hole. If you have desoldert it, put the LED display from the fan controler in the right hole. Then superglue the nuts in the nutholers and glue 2 short ones up in the corners, behind the switch and 2 long ones in the lower corners. All flush with the back of the housing. Note: Toothpaste is a very good thermal conductor, but proper thermal paste, indium strips or liquid metal are much better. I paid approximately 25 Euros for the electronics on amazon, but I had to wait a few months for them, if you spend a little bit more, they will arrive much faster. I´m going to add the Fusion 360 files soon. If you have questions, or if you need another backplate, for another battery-brand, and you can´t design it on your own, just write a comment.