Overview

These lamps were designed as fully functional, gift-ready products that combine custom 3D-printed components with off-the-shelf lighting hardware. Each lamp uses a standard E26 light bulb housed inside a 3D printed enclosure, with removable lithophane panels that transform photographs into illuminated images.

Design Goals & Constraints

• Integrate standard E26 bulb and socket hardware
• Create interchangeable lithophane panels (“slides”)
• Ensure safe clearances, heat dissipation, proper fit, and ease of assembly
• Design for repeatable 3D printing and gifting
• Allow the lithophane holder to rotate independently of the base, so the user can view different lithophanes without turning the base and tangling the cord

Mechanical Design

Special attention was paid to tolerances and part interfaces so that printed components would fit reliably with commercially available lighting hardware without modification.

The standard E26 base also makes the bulb easy to replace if it burns out, or to swap for a Wi-Fi-controllable bulb.

Manufacturing & Materials

All structural components were 3D printed in PLA. The bulb threads into an off-the-shelf brass lamp base, so the printed housing wraps that base rather than sitting against the bulb itself, and a vent in the top lets hot air escape. With that arrangement, the PLA was validated against a 100W incandescent bulb for over 24 hours without deforming.

Lithophanes were generated from photographs and printed to achieve consistent light transmission and image clarity when illuminated.

Print orientation, wall thickness, and part layout were selected to balance strength, surface quality, and print time. Where possible, multiple components were designed to be printed together on a single build plate, improving manufacturing efficiency and reducing total production time.

I used itslitho.com to convert existing images into lithophane STL files for printing.

From these test prints, it was determined that all slides going forward would be printed in the vertical orientation for optimal quality.

Outcome

The final design resulted in a functional, repeatable lamp that can be customized with different images while using the same core hardware and 3D printed components. These lamps have been produced as gifts for friends and family, validating the design through real-world use and handling.

Future Improvements

LED-Based Light Source: A future revision could replace the E26 bulb with an internal LED strip or module, allowing for more uniform light distribution, reduced heat, and a slimmer overall housing design.

Motorized Panel Rotation: Another potential enhancement would be a small internal motor to automatically rotate the lithophane panel assembly. The current design allows manual slide rotation, but a motorized system could enable continuous image rotation or timed transitions.

Overview

This project involved designing a custom 3D-printed cupholder solution for the rear seat of a 2017 VW Jetta that shipped without factory-installed rear cupholders. The design integrates with existing interior features and requires no permanent modification to the vehicle.

Design Approach

The cupholders clip onto the existing rear storage cubby and transfer load to the floor tunnel, using multiple contact points to improve stability. The geometry was designed to fit within the tight constraints of the rear seating area while maintaining passenger comfort and ease of use.

I chose Tinkercad for this project due to its simplicity and accessibility, as I didn’t have Fusion 360 at the time. While Tinkercad is not ideal for complex mechanical designs, it provided all the modeling functions I needed to quickly prototype and iterate this small, functional component.

Manufacturing

The cupholder assembly was 3D printed, with part geometry and print orientation selected to balance strength, durability, and print time.

An initial 2-cup prototype was printed in PLA, but the material deformed from heat, so the final 4-cup design was printed in PETG for improved thermal resistance.

The jump to 4 cupholders came from user feedback, giving passengers more storage. The design was iterated to ensure reliable fit and retention when installed and removed.

Outcome

The final design provides a stable, removable rear-seat cupholder solution that integrates cleanly with the vehicle interior and has been validated through regular real-world use. Multiple variations were created:

• Configurations for 2, 3, or 4 cups at full height, with the final design (yellow) using 2 cups at full height and 2 cups at half-height to balance capacity and passenger room.
• A more square-shaped version designed to fit neatly in the car, offering a cleaner aesthetic compared to the original 4-lobed layout.

Future Improvements

Increased Cup Spacing: A future revision could increase the spacing between cupholders to better accommodate larger bottles or cups. In the current design, spacing was intentionally limited to avoid reducing rear-seat foot room, prioritizing passenger comfort over maximum cup size.

Overview

This project began as a small but recurring layout issue in my apartment bathroom. The towel rack mounted above the toilet sits low enough that hanging a towel prevents storing a spare roll of toilet paper on top of the tank. Since the towel rack couldn’t be moved, the problem became one of repositioning the spare roll without modifying the bathroom.

The goal was to design a compact, non-permanent holder that attached directly to the toilet tank and relocated the roll off to the side. Key constraints included maintaining clearance for the towel above, keeping the roll easily accessible, and avoiding interference with a nearby trash can whose lid opens upward. The solution also needed to be stable, visually unobtrusive, and compatible with standard toilet paper rolls.

I designed and 3D printed a side-mounted holder that securely attaches to the toilet tank and stores the roll horizontally. The final placement keeps the roll low and outboard, preserving towel clearance while maintaining full trash can functionality. The geometry was tuned to balance rigidity, clearance, and ease of installation, resulting in a simple, durable part that integrates cleanly into the existing space.

This project demonstrates my approach to practical, constraint-driven design: identifying real-world limitations, designing around fixed hardware, and rapidly prototyping a functional, low-impact solution.

Planning

Measuring

3D Design Timelapse

This design was completed in about 15 minutes using Fusion 360.

Slicing Timelapse

A quick timelapse of the slicing process, comparing different print orientations.

3D Print Timelapse

This print took about 3 hours to complete (2.5 hours estimated, plus an extra 30 minutes for the timelapse).

This was printed with a 0.4mm hardened steel nozzle, using black Overture PLA, on a Bambu Lab A1.

Final Outcome

Problem Statement

OEM headlight performance on the 2017 Volkswagen Jetta proved insufficient for safe nighttime driving on rural, unlit backroads. Limited long-range visibility increased the risk of delayed hazard detection, particularly for wildlife such as deer, prompting the need for additional forward lighting.

Design Goals

• Improve long-range forward visibility to increase reaction time when driving on rural, unlit backroads.
• Enhance visibility in adverse weather, particularly snow and low-contrast conditions.
• Maintain full street legality across all U.S. states for normal on-road operation.
• Enable independent operation of the auxiliary lights, allowing use when stationary (e.g., camping or assisting another driver) without relying on the vehicle’s primary lighting system.
• Ensure intuitive, low-distraction interaction while driving.
• Achieve an OEM-like interior appearance, with controls and indicators that integrate cleanly with the existing cabin design.
• Provide clear driver feedback via a visible interior indication when auxiliary lights are active.

Design Constraints

• No permanent modifications to the vehicle, including no drilling into the bumper, body panels, or interior trim.
• Full reversibility, allowing the auxiliary lighting system to be completely removed and the vehicle returned to stock condition if desired.
• Durable, weather-resistant components capable of withstanding rain, snow, road debris, and automated car washes.
• Mounting height and placement must avoid reducing ground clearance or risking contact with road obstacles, given the Jetta’s already limited ride height.
• Low electrical load, favoring LED or other low-wattage lighting to minimize battery drain and avoid overloading existing electrical systems.
• Preserve OEM electrical behavior, ensuring the auxiliary system does not interfere with factory lighting, diagnostics, or vehicle operation.
• Electrical safety and reliability, including proper fusing, grounding, and load management.
• Serviceability, allowing individual components to be accessed or replaced without disassembling unrelated systems.
• Noise and vibration resistance, ensuring stable operation under real-world driving conditions.

Solution Overview

Interior. The 2017 Volkswagen Jetta is offered across multiple trim levels, with higher trims featuring a headlight switch that includes factory fog light controls. Although the base trim does not include fog lights, the interior wiring and switch form factor are compatible across trims. To maintain an OEM appearance and intuitive user interaction, a higher-trim headlight switch with fog light functionality was selected. The fog light switch signal was repurposed as a control input for the auxiliary lighting relay, allowing the off-road lights to be activated using a factory-style control without adding visible aftermarket switches to the dashboard.

Exterior hardware. To avoid permanent modifications to the vehicle, the auxiliary lights were mounted using a license-plate-based bracket that attaches to the existing four front license plate fasteners. This approach enabled a secure mounting solution without drilling into the bumper or body panels. The lights were positioned below the front license plate to preserve plate visibility and maintain compliance with legal and safety considerations.

For illumination, 3-inch LED spot light pods from Harbor Freight were selected as a balance between cost, durability, and performance. Spot-pattern lights were chosen specifically to maximize down-road visibility and improve reaction time at higher speeds, rather than providing wide-angle flood lighting intended for low-speed or off-axis illumination.

Electrical. The electrical system uses an off-road lighting kit with a fused relay connected directly to the 12V battery, isolating it from the factory circuits. Two control paths were implemented: OEM-style operation via the upgraded headlight switch (which requires the parking lights to be on to activate the fog light circuit), and independent operation via the kit’s toggle switch, mounted near the OBD-II port. This setup allows the lights to function either as integrated driving lights through the fog light switch or independently, minimizing battery draw by avoiding unnecessary activation of other OEM lighting.

Execution & Implementation

The project began with mounting the Harbor Freight 3-inch LED spot lights using a license plate-based bracket, which was originally designed to position the lights above the front license plate. During mock installation, it became clear that mounting them above the plate partially blocked the license plate, which could create a legal issue. To address this, the bracket was mounted below the license plate, maintaining full plate visibility while providing a secure attachment point for the lights.

Ground clearance and approach angle were evaluated prior to finalizing light placement. Because the Jetta sits relatively low, the lights were positioned to maximize forward visibility without reducing clearance or risking contact with road obstacles. Measurements and mock placement ensured that the lights would not interfere with normal driving over bumps, curbs, or steep inclines.

Routing the relay control wire through the vehicle’s firewall required careful planning. The wire was run alongside existing factory harnesses to ensure protection from chafing, heat, and moving parts, preserving electrical safety while isolating the auxiliary system from OEM circuits. Excess wire was carefully bundled and zip-tied between the radiator and bumper, keeping it clear of fans, belts, and other moving components. While this placement does leave the wires vulnerable in the event of a collision, the trade-off was acceptable, as cutting or shortening the wire further could have introduced additional potential failure points and reduced cable longevity.

Initial testing revealed that the stock LED pods produced a very cool, blue-toned light, which reduced visibility in rain, snow, fog, and dust. Orange lens covers were added to shift the beam to a warmer yellow-orange hue, improving contrast and making obstacles easier to detect in low-visibility conditions.

Finally, the interior installation of the upgraded fog light switch provided OEM-style control, while the toggle switch mounted near the OBD-II port enables independent operation. This dual-control setup allows the lights to function as integrated driving lights or independently, preserving battery life and ensuring functionality in both driving and stationary scenarios.

Validation

Testing was conducted in a low-light park (top three) and an unfinished housing development (bottom three) to safely evaluate beam pattern and visibility improvement without stopping on public roads. The orange lens covers were removed for this testing.

Results

The auxiliary lights have been in service for over 60,000 miles across nearly three years of real-world use (installed in October 2023), including multiple Minnesota winters. They have performed reliably through snow, heavy rain, hail, high winds, car washes, and minor incidental contact without failure or degradation. The lens covers provide both physical protection when the lights are not in use and ensure compliance with street-legal lighting requirements across all U.S. states.

Future Improvements

While the current system has proven reliable and effective, several enhancements could further improve functionality, usability, and flexibility. One potential improvement would be replacing the removable lens covers with dual-color or multi-color LED light pods, allowing color temperature to be adjusted electronically based on driving conditions rather than manually. This would enable quick adaptation between clear, snowy, or dusty environments.

Additional improvements could include integrating automatic control logic, such as disabling the auxiliary lights above a certain vehicle speed or when high beams are not active, to further enhance safety and compliance.

From an electrical perspective, adding current sensing or fault detection would allow the system to alert the driver to wiring or light failures in real time. Finally, a revised mounting solution that positions the lights slightly higher, while still preserving approach angle and legality, could further improve down-road illumination without compromising ground clearance.

Project Overview

This project is a fully custom, battery-powered Bluetooth speaker designed for outdoor environments where durability, water resistance, and sound quality are equally important. Intended for use around lakes, campsites, and boats, the speaker was engineered to survive splashes, rain, and accidental immersion, while still delivering powerful, controllable audio and long runtime from a common power tool battery.

The final build integrates dual marine speakers, a high-power Bluetooth amplifier, physical media controls, and auxiliary power output, all housed in a rugged, waterproof enclosure designed to float if dropped into water.

Design Goals & Constraints

Key design requirements included:

• Waterproofing: All components and enclosure penetrations needed to resist moisture and splashing.
• Flotation: The speaker should remain buoyant if it falls into a lake or river (e.g. off a canoe).
• High output audio: Sufficient power to drive large speakers in outdoor environments.
• Battery ecosystem compatibility: Use of a DeWalt 20V Max battery for easy swapping and extended runtime.
• Standalone usability: Physical controls for audio and media playback without relying on a phone.
• Perceived build quality: The speaker should feel solid, intentional, and robust, not hollow or improvised.

Enclosure & Mechanical Design

The system is housed in a Harbor Freight Apache 3800 case, selected for its rugged construction, integrated gasket seal, and cost-effective waterproof design. The case provides both impact resistance and environmental protection while offering enough internal volume for large speakers and electronics.

Two 6.5" marine-rated speakers were mounted directly into the case. Marine speakers were chosen specifically for their resistance to moisture, humidity, and corrosion, making them well-suited for outdoor and near-water use.

To improve both sound quality and perceived durability, adhesive-backed sound-deadening material was added to the interior of the enclosure. This serves multiple purposes:

• Reduces unwanted vibrations and resonance inside the case
• Improves acoustic response by minimizing hollow or “boxy” sound
• Adds mass to the enclosure, making the entire assembly feel more substantial and rugged

All mechanical penetrations, including speaker mounts and control interfaces, were carefully sealed to preserve the case’s waterproof integrity.

Power Architecture

The speaker is powered directly from a DeWalt 20V Max (nominal voltage: 18V) battery using an internal battery adapter. This approach eliminates the need for a custom battery pack while providing long runtimes and easy battery replacement using commonly available tool batteries.

An in-line fuse protects the battery in the unlikely but possible event of a catastrophic short.

To support auxiliary electronics, a step-down (buck) voltage converter was added to reduce the 18V battery voltage to 5V. This 5V rail powers:

• A USB output port, allowing the speaker to charge any 5V USB device
• A 5V LED power indicator

Amplifier & Housing

At the core of the system is a T100HS-W Bluetooth power amplifier board, featuring a TPA3221 Class-D amplifier chip capable of delivering 100W × 2 channels. This amplifier was chosen for its high output power, efficiency, and integrated Bluetooth 5 functionality, making it well-suited for a battery-powered, high-volume outdoor speaker.

Early testing used a fully enclosed 3D-printed amplifier housing, but it trapped too much of the heat the amplifier produced, causing the PLA to start deforming and the board temperature to climb past 65°C.

This amplifier is now housed in an open-top 3D printed housing. The 3D printed housing is glued onto the layer of foam below it, and also nested by the surrounding layer of foam. 3 elastic bands are used to hold the amplifier board in the housing. These bands were chosen to allow air circulation around the amplifier board's heatsink. The highest temperature on the amplifier board recorded during testing was 50°C. This reduced operating temperature will help extend the lifespan of the amplifier.

Controls & User Interface

A dedicated external control panel (daughter board) was mounted to the outside of the enclosure, allowing full control without opening the case or relying on a connected device.

The control panel provides:

• Volume adjustment
• Bass and treble tuning
• Media controls (play/pause, next track, previous track)
• Amplifier controls (power on, power off, bluetooth pairing, input select)

In addition, the Bluetooth amplifier supports custom device naming, so the broadcast name can be changed from a generic identifier to something recognizable. This small but meaningful detail improves the experience, especially in environments with many nearby Bluetooth devices.

User testing revealed the potential for confusion around the three identical dials. To address this, a simple 3D-printed adapter that selectively covers the bass and treble adjustment knobs was designed, strongly prioritizing the primary control. The adapter attaches using two embedded magnets that interface with the screws securing the control panel to the housing. This approach provides a secure, stable connection during use while remaining easily removable when tonal adjustments are desired.

Integrated Phone Storage & Mount

To improve usability in outdoor environments, the speaker includes a dedicated internal storage area for a phone. With external media controls already available, this allows the phone to be protected while the speaker remains fully usable. Several approaches were explored to achieve a secure, adjustable solution.

• Early custom 3D-printed holders accommodated multiple phone sizes but did not provide sufficient retention.
• Final design uses a commercially available car phone holder for strong clamping and adjustability. This holder is connected to a 3D-printed 17 mm ball mount, which is glued to the base of the speaker. This combination enables the ideal location for the phone in the speaker.
• The 5V USB port sits close to this mount, so a phone can charge while stored in the speaker. A USB-A to USB-C adapter is also stored inside to accommodate different charging cables.
• The assembly has proven durable in use, withstanding several unintended drop events while continuing to hold the phone securely.

Waterproofing Strategy

Maintaining water resistance was a key design focus throughout the build. Beyond the case’s built-in gasket seal, silicone adhesive was used extensively at critical interfaces to ensure long-term waterproofing and vibration resistance.

Silicone adhesive was applied to:

• Seal component interfaces and penetrations
• Provide strain relief and vibration damping for internal electronics

This approach ensures that both mechanical and electrical connections remain protected even in wet or high-vibration conditions.

Flotation & Outdoor Use Considerations

Component placement and material choices were made with buoyancy in mind. By preserving internal air volume and carefully managing weight distribution, the speaker is able to float if accidentally dropped into water, rather than sinking and becoming unrecoverable.

These considerations make the speaker particularly well-suited for:

• Canoeing and kayaking trips
• Lakeside and beach use
• Campsites and off-grid environments

Outcome & Takeaways

The completed speaker delivers loud, clear audio with strong low-end response, long battery life, and excellent durability in outdoor conditions. By combining off-the-shelf components with thoughtful mechanical, electrical, and environmental design, the project achieves a balance of performance, reliability, and usability.

This project highlights skills in:

• Power electronics and voltage regulation
• Audio system integration
• Waterproof mechanical design
• User-focused interface design
• Designing for real-world environmental constraints

Overall, it represents an end-to-end DIY product build that prioritizes robustness, serviceability, and real-world usability, not just functionality on a workbench.

Compact Version

A second iteration of the speaker system was developed with the primary objective of reducing overall enclosure size while maintaining strong acoustic performance. This version was built around an Apache 1800 protective case, using the rugged, gasket-sealed housing as the primary enclosure structure. Leveraging an off-the-shelf case reduced custom fabrication requirements while providing durability, impact resistance, and inherent portability.

To achieve a smaller and cleaner external profile, the volume, bass, and treble controls were relocated inside the enclosure. While still fully adjustable, modifying these parameters requires opening the case, allowing the exterior to remain compact and sealed. Smaller drivers were selected to fit within the constrained internal geometry, and mounting structures were designed to ensure rigidity and minimize vibration within the plastic shell.

The speaker grilles were custom 3D-printed in TPU, providing a flexible and impact-resistant protective layer that resists cracking while remaining acoustically transparent. Despite the reduced scale and simplified interface, careful component selection and tuning enabled the system to retain strong clarity and output relative to its size, demonstrating effective management of mechanical, acoustic, and usability tradeoffs.

Future Version Considerations

While the current design meets the original goals, a future iteration would focus on expanding versatility and refinement rather than changing the core architecture.

One area for improvement is enclosure color options. The Apache 3800 case was limited to orange, black, and tan. Black raised concerns about heat absorption during extended sun exposure, while tan was less visually appealing for this application, leaving orange as the most practical choice. A V2 would explore alternative cases, coatings, or finishes that offer better thermal performance and greater visual customization.

Another opportunity is broader battery compatibility. The current system uses a DeWalt 20V Max battery, chosen for availability and performance. Future versions could support interchangeable battery adapters or a more modular power input design, allowing the speaker to work across multiple tool battery ecosystems or with a dedicated internal battery pack.

Finally, a V2 would ideally integrate an external LED work or scene light, controlled by a dedicated button. This addition would extend the speaker’s usefulness beyond audio, supporting campsite lighting, low-light task work, or general outdoor illumination, further positioning the device as a multi-purpose outdoor utility platform.