This is a project to repair a Black Diamond Sprinter headlamp. This was my favorite headlamp until I broke the tabs that hold the battery pack to the headband. It definitely would have been a better use of time to buy a new one, but it was also a good opportunity to practice my 3D scanning, CAD modeling, and 3D printing.

The process was to:

1. Disassemble the headlamp
2. Scan the broken part
3. Import the surface model into Fusion 360
4. Make a solid model of the part
5. Design a more robust clip
6. Print a final part in PETG
7. Reassemble the headlamp

I chose PETG because it would be slightly more flexible and more resistant to shattering than the original part.