How can i make this whole thing work with just 3D printed parts, i wanted to just use standard parts and no glue.

Threaded inserts and glue would have made the whole design much smaller and sleek.

There were many design iterations but in the end, this is what i settled on:

http://imgur.com/a/kyIV1

The next step was to print all the parts and see how well they fit together, luckily everything worked out on the first try.

The PCB was printed and heatsink were printed as well, to check for clearance, and minimize surprises:

http://imgur.com/a/74eIh

From here the LED head and heatsink had to be constructed, the heatsink was build out of regular 1.5mm aluminium, test runs showed that this will stay cool enough for now, but ultimately thermal management will have to be implemented and a custom metal core PCB will have to be used.

http://imgur.com/a/8NPsd

After this was done there were a few test and trial with different lenses, reflectors and window designs.

Sadly there are no pictures of that.

A single 10mm Carclo lens was chosen, it is not build for this LED but does work well enough.

After this the electronics had to be build.

The PCB is double sided and etched at home, the bottom layer holds all the power circuitry and the top side holds the processor, buttons and LEDs, this reduces the need for many vias and keeps the work on a double layer board at a minimum.

Everything could have fitted on one side but i solder the parts by hand and do not use reflow soldering, except for the ICs, those are soldered with hot air.

Especially the LED driver has to be soldered with hot air, it will fail if soldered with an iron:

http://imgur.com/a/ZhKEt

At this point i had to face the reality that the buttons design will not work as intended and had to design a solution that would work with the already printed parts, this was the rough draft after much thinking:

http://imgur.com/a/0a07o

It took a few tried to get the thickness of the spring arms just right, this was the 4th try, which worked out in the end:

http://imgur.com/a/dj6pB

But, the whole thing came together and seems to work pretty well, all things considered:

http://imgur.com/a/cvmrh