TableLight

TableLight

A 3D-printable, battery-powered, USB-C rechargeable table lamp in the classic "Poldina" shape - honeycomb disc base, thin stem, down-firing cone shade with a white top - running WLED on an ESP32, with a capacitive touch pad hidden under the white top plate.

What is in this repository

cad/tablelight.py          parametric CAD (Python: trimesh + manifold) - ALL dimensions live here
cad/stl/                   ready-to-print STL files (6 parts)
hardware/pcb/              custom controller PCB: SKiDL circuit, KiCad 7 board (kicad/), PCBWay fab package
                           (fab/: Gerbers, drill, BOM, pick-and-place), board generator, design notes
firmware/wled/             WLED build override + settings for this lamp
docs/BOM.md                complete bill of materials (printed parts, electronics, hardware, consumables)
docs/PRINTING.md           print settings and orientation per part
docs/ASSEMBLY.md           step-by-step build
docs/WLED_SETUP.md         WLED configuration (pins, 2D matrix, touch button, battery, current limit)
docs/images/               renders, section drawing, PCB placement, block diagram

The parts

Section through the assembled lamp (all clearances are modelled, nothing is glued):

Electronics in one picture

Power path: USB-C -> TP4056 charger -> 1S pack (DW01A/FS8205A protected) -> load-share (Schottky + P-FET) -> VSYS -> MT3608 boost 5.1 V -> P-FET LED switch -> LED ring in the head (via the stem); VSYS -> 3.3 V LDO -> ESP32-WROOM-32E. The USB-C data lines go to a CH340C with auto-reset, so WLED is flashed through the charging port. A slide switch in the base wall is the hard off (about 80 uA drain). WLED's "relay pin" cuts the LED rail so standby is only the ESP32.

See hardware/pcb/README.md for the design rationale and hardware/pcb/SCHEMATIC.md for every net.

Build order (short version)

1. Print the six parts (docs/PRINTING.md). Fit 12 x M3 heat-set inserts.
2. Order the PCB: upload hardware/pcb/fab/tablelight-gerbers.zip to PCBWay (hardware/pcb/fab/README.md has the form values). Flash WLED (docs/WLED_SETUP.md).
3. Tape the LED ring into the head plate, stick the touch foil in its recess, run the wires down the stem (docs/ASSEMBLY.md).
4. Screw the stem to the deck, plug the PCB in, screw the PCB to the deck bosses, fit 1 or 2 cells, screw the floor on.
5. Push the diffuser up into the cone, screw the cone to the head, push the head onto the stem and fix it with two screws. Done.

Regenerating the CAD / PCB files

pip install -r requirements.txt
python3 cad/tablelight.py                    # STLs -> cad/stl, renders -> docs/images
python3 hardware/pcb/tablelight_netlist.py   # tablelight.net, bom_pcb.csv, SCHEMATIC.md
python3 hardware/pcb/board_outline.py        # outline.dxf, placement.svg, PLACEMENT.md
python3 hardware/pcb/build_board.py          # KiCad board -> autoroute -> DRC -> fab/ (needs KiCad 7 + freerouting.jar)
python3 docs/block_diagram.py                # block_diagram.svg/.png

Change a value in the P = dict(...) block at the top of cad/tablelight.py (shade size and taper, stem length, base diameter, honeycomb size, ring diameters...) and everything that depends on it - head socket, cone screw positions, wall openings, PCB placement drawing - follows. The stem is 236 mm tall as printed; set stem_len lower if your printer's Z is under 240 mm.

Safety notes

• Cells in parallel must be the same model and within ~0.1 V of each other when inserted. Never mix a fresh and a flat cell.
• The board has over/under-voltage, over-current and short protection (DW01A + FS8205A), but a lamp is a closed plastic box: keep the WLED current limit at or below 1200 mA and do not leave it charging on a cushion.
• Use a 5 V USB-C supply rated 2 A or more when charging and running at the same time.

License

MIT for the code and design files. WLED is licensed separately by its authors.