Utility head strap (headband)

Edited 3 May 2023

Added a forehead plate insert that can interface attachments from my other project, PlastiClamp

Edited on 02 December 2022

I added a forehead plate for sliding dovetail mounting system. 

It happens that the flashlights sold at Costco fit almost perfect. 

There are two pockets for M4 hex nuts.

Tightening the M4 screw will push the pad and apply force against a mating component.

Below are the nominal dimension of the mating part if you plan to build your own attachments. You may need to adjust the dimensions based on the filament type you are planning to use for the attachment.

I also added a “forehead plate with dovetail and front slots”. If you plan to often switch attachments, slide inside the slot a thin metal plate to prevent the screw pushing directly against plastic surface

Initial model  release.

I used ASA filament to print the parts. I didn't use support, just 3mm brims for the front and back plates. There are some strings due to long bridges on the horizontal slots for the webbing but they are not visible after assembly.

You will need nylon webbing strap 1 ½" wide, for example this one https://www.amazon.com/gp/product/B09QJ4T22W/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

 Cut the appropriate length and with a hot blade seal the cut ends to prevent fringing. 

The front plate has two pockets to hold M4 hex nuts and corresponding  M4 screw holes to mount various attachments. 

(a test model for a pupilometer attached).

Adjustable pressure and flex buckle to provide more comfort.

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Below is a guide on how I routed the nylon straps.

The pressure adjustment screw from the back is left-hand. 

Component list

https://studio.youtube.com/video/Id5eiWAHVyM/edit