FlashKa Keychain v0.7 - the files to upload, one folder per shop. Step by step, option by option: FlashKa_v0.7_Build_Guide.pdf (one folder up), section 3 (JLCPCB), section 4 (JLCCNC and JLC3DP, one merged order), section 5 (the rubber for the side keys) and section 9 (casting the keys). Section 6 lists the parts you buy ready-made. FlashKa has not been built yet: read the guide's status note before you spend money. No part of the light is 3D-printed and nothing is laser-marked; the only print is the casting mould of the side keys, a tool. 1_JLCPCB jlcpcb.com Both circuit boards in one panel - the main PCB with the 1000 lm power stage and the key board - with all small parts mounted on both sides. Guide section 3. FlashKa_panel_gerbers.zip the Gerber file: one panel = 1 key board + 1 main PCB + two 6 mm rails, 45.0 x 32.5 mm. FR-4, 4 layers, 0.8 mm, ENIG, BLACK solder mask, white silkscreen, 5 panels (the minimum). Delivery format "Panel by Customer", panel format 1 x 1, "Different Design" 2 (two different boards in one file: JLCPCB adds a surcharge for it, shown after the upload). BOM_JLCPCB.csv PCB Assembly: Standard, both sides, 2 panels (the minimum), "confirm parts placement". 35 lines, 79 parts per panel (60 on the main PCB, 19 on the key board). R3 is 2.0 k (LCSC C4109, a Basic part): it sets the 500 mA charge of the 14500 cell, which is bought separately. CPL_JLCPCB.csv where each part goes on the panel and how it is turned. Check the placement preview before you pay: pin 1 of every chip. On the main PCB's top face the buck U2 (3 x 3 mm QFN, no leads) has pin 1 at the corner nearest to the inductor L1 (towards the USB-C opening); on its bottom face the protection IC U6 sits right above the dual MOSFET Q3, both turned the same way (pin 1 of each on the side nearer to the battery pads). The switches SW1-SW3 and the ring LEDs LED3 and LED4 are on the bottom side of the key board (left board), the six gold pogo pins P1-P6 on its top side; the main PCB's six round gold pads J6 (bottom side) get no part. Edge rails and fiducials: "by customer" (the rails carry 3 fiducials and 4 tooling holes). If JLCPCB's review asks for a bigger panel for Standard assembly, accept the edge rails it offers. Pogo pins: Harwin P70-1010045R, LCSC C22100007, 6 per light. If the JLCPCB parts library shows no stock when you upload the BOM, buy them into your JLCPCB parts library first (Parts Manager, order parts from LCSC stock), then place the order. Extended parts of the 1000 lm power stage - check their stock when the BOM is uploaded: buck TI TPS62095RGTR (LCSC C139643), cell protection IC DW01A (LCSC C351410), dual MOSFET SINO-IC SE8830A (LCSC C238645). The SE8830A has no drop-in substitute: a common 8205A-type dual MOSFET has about twice the on-resistance, and the DW01A would then cut the light off in turbo (trip at about 2-3 A). If a part shows no stock, buy it into your JLCPCB parts library from LCSC stock (as for the pogo pins) or wait for stock. Before you order, check the SE8830A pin assignment: its LCSC data sheet shows it only as a package picture. Pins 1-6 must be S1, D, S2, G2, D, G1 (as on the FS8205A); the board is laid out for exactly this order, and a part with another pinout would disable the protection or short the cell. Optional: "inner copper weight 1 oz" instead of 0.5 oz (a small surcharge in the quote) halves the resistance of the 2 mm battery strip inside the board; the board is designed for 0.5 oz. After delivery: break both boards out of the rails at the small perforated tabs and file the 0.3 mm nubs flush (2 on each long side of each board). The key board fits the housing either way round - only one way is right. Its white silkscreen shows how: top face (the side with the six gold pins) "<- HEAD" (the arrow points to the LED head) and "PINS: S2 SIDE" (the pins go to the S2 / laser side, away from the USB-C opening); bottom face an arrow between the switches that points to the head as well. Guide section 12.4. Fall-back only: production/ (one folder up) also holds each board on its own (FlashKa_main_gerbers.zip, FlashKa_keys_gerbers.zip with their BOM and CPL files; the key board is 4-layer like the panel). Two separate orders pay the set-up, stencil and board fees twice. 2_JLCCNC jlccnc.com Machined parts: aluminium tray and lid, clear PMMA main keys, black POM-C parts. Guide section 4. One merged order with the resin mould of 3_rubber_keys (JLC3DP): one parcel, one shipping rate. Body: octagon 20 x 18 mm (facets 13.2 bottom / top, 11.2 sides, 4.81 diagonals), 99.2 mm long; the lid is the cap above the upper facet edges (3.4 mm tall), pocketed from below over the cavity, with a flat seat (flat to 0.05 mm, drawing FK-H-02). FlashKa_tray.step + FlashKa_tray.pdf (2 sheets) 6061-T6, bead blast + black anodise, no marking; 1 per light FlashKa_lid.step + FlashKa_lid.pdf same as the tray; 1 per light FlashKa_pmma_kit.step + FlashKa_pmma_kit.pdf clear cast PMMA, polished: 3 main keys (1 + 2 spares) on tabs in a frame; ROUNDUP((lights + 1) / 3) kits FlashKa_pom_kit.step + FlashKa_pom_kit.pdf POM-C black: lid RF window insert (+1 spare) and antenna spacer on tabs in a frame; 1 kit per light JLCCNC machines plastic parts only from 30 x 20 x 8 mm up, so the small PMMA and POM-C parts are ordered as these two kits (52.8 x 22 x 8.5 mm and 45.4 x 39.3 x 17 mm). On arrival: cut the tabs, file flush, then polish the PMMA keys if the shop did not. Shops that take small parts can use the single files in the same folder (FlashKa_key_main.step + FlashKa_key_main.pdf, FlashKa_rf_window.step, FlashKa_antenna_spacer.step + FlashKa_pom_parts.pdf). FlashKa_laser_sleeve.step (POM-C) is only for a laser module thinner than 6 mm and is not in the kit. Each drawing has the name of its STEP file: upload the two together. The tray has 7 threads (4 x M1.6 for the lid, 2 x M1.6 BLIND for the key board, 1 x M1.6 from the top of the head block into the laser bore for the laser set screw, under the lid). Every metal wall is at least 0.5 mm (JLCCNC's absolute minimum); below the recommended 0.8 mm are only the two front lid taps behind the optic bore (0.51 mm at the thread root) and the upper LED wire groove (0.751 mm): name them in the quote chat (drawing FK-H-01, note 7). The panels of the tray and lid carry a 0.2 mm V texture cut with an engraving cutter: ask for it in the quote (the parts work without it). It is a priced option in the workbook: to leave it out, ask the shop to skip feature 17 of drawing FK-H-01, because the STEP files carry it. No glass window and no spacer ring: the LEDiL LISA3-RS-PIN TIR optic (bought; pins cut off, glued into the head bore with two-part epoxy, no cyanoacrylate) stands on the LED board. Bought parts too: the two hold-down pads, the stainless steel screws (lid: 4 x M1.6 x 6 countersunk), polyimide tape for the two cell rails and 0.5 mm closed-cell foam sheet for the cell's strip under the lid and its tail pad. The aluminium casting mould of the side keys (files in 3_rubber_keys) is a JLCCNC part, but only for builders who choose it over the resin mould: once per builder, not per light. Details: 2_JLCCNC/README.txt 3_rubber_keys cast at home: urethane rubber (or Sugru) in a resin mould (JLC3DP) or an aluminium mould (JLCCNC). The two side keys. Guide sections 4, 5 and 9. FlashKa_key_side.step cast rubber body, one piece, 0.47 mm recess for the stiffener in the inner face FlashKa_key_stiffener.step stiffener: plate 3.6 x 9.4 + doubler 2.0 x 2.0, 0.3 mm stainless steel shim FlashKa_key_side_with_plate.step rubber body + stiffener as glued FlashKa_key_side.pdf drawing FK-H-04: Shore A 80 black, stiffener outline, gluing FlashKa_key_mould_resin_cavity.stl resin mould part for JLC3DP (SLA): cavity half, 48 x 28 x 6.0, ribbed back - the default mould FlashKa_key_mould_resin_lid.stl resin mould part for JLC3DP (SLA): lid, 48 x 28 x 5.0, ribbed back FlashKa_key_mould_resin.step the resin mould closed with its 4 M3 x 16 bolts (reference) FlashKa_key_mould.step aluminium mould, closed: cavity half, lid, 2 dowel pins, 4 M3 screws (reference) FlashKa_key_mould_cavity.step aluminium mould part for JLCCNC, 6061-T6, cavity half bead blasted FlashKa_key_mould_lid.step aluminium mould part for JLCCNC, 6061-T6, as machined FlashKa_key_mould.pdf drawing FK-H-08: both moulds (tolerances, cutters, assembly) The mould is a tool, not a part of the light: one per builder. Default: the resin print (JLC3DP, the cheap choice, in the merged order with JLCCNC; printed pins, 4 M3 x 16 through bolts with washers and nuts; print with the parting face up). Durable option: the aluminium mould (JLCCNC). Both have the same four cavities: one pour casts 4 keys (2 + 2 spares); 2 per light (next and previous are the same part, turned 180 degrees). Rubber: Smooth-On ECON 80 (Shore 80A, 1A:1B by volume, no scale needed) with black pigment - the default of the parts list; Sugru (Shore 70A, pressed in by hand) is cheaper but softer; PMC-780 DRY also works. A mould release goes on before every cast (urethane: a urethane mould release; Sugru: petroleum jelly). The stiffener is cut from 0.3 mm stainless steel shim with tin snips (or laser cut) and glued in with cyanoacrylate (Sugru keys: with fresh Sugru). The chevron points along the body: held like a presenter the key nearest the head reads "^" (next) and the key nearest the hand "v" (previous). Details and casting steps: 3_rubber_keys/README.txt optional_laser_label NOT part of the normal build. FlashKa_laser_label_lid_class2.dxf / .png laser warning label for the lid, only for a light that is sold or given to others (EN 60825-1). The v0.7 light itself carries no marking; the label is printed in the build guide (section 1, "Laser safety") and goes on the packaging. It fits the lid panel over the main board (X 13.49 to 32.25, Y +/-4.9; text about 0.87 mm high). Details: optional_laser_label/README.txt Not in these folders: the 14500 cell (Vapcell INR14500 F15 from an EU battery shop) with 0.2 mm nickel strip for its tabs (welded on with a small spot welder, unless the cell comes with welded tabs: never solder onto the cell), the LED board, the TIR optic (a pack of 5 from an electronics distributor), the laser module, the screws, the set screw, the split ring, the silicone pads, the 24 AWG wire, thermal paste, tapes, foam, two-part epoxy and other adhesives, the resin mould's M3 bolts with washers and nuts, and the casting supplies (urethane rubber, pigment, mould release, stainless shim, cyanoacrylate). Guide sections 5 and 6; workbook FlashKa_Parts_List_v0.7.xlsx, sheet "Bought parts".