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