DIY, Open-Source Headlamp Design

Bosavi LLC is a Berkeley, Calif., startup company launching a headlamp “designed to be charged from almost any power supply.” On a Kickstarter video company founder Dan Freschl is shown recharging the little white headlamp using a solar unit, a USB computer cord, and some kind of whizzing, cord-pull electro generator that serves as a mini power station in the outdoors.

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Founder Dan Freschl with the Bosavi rechargeable headlamp; photo by Joseph Schell

The company’s namesake headlamp was made, Freschl says, to stop wasteful battery usage. It was a design “borne out of years of frustration at the inconvenience and environmental impact of AAA-powered headlamps,” he wrote.

Instead of disposable batteries, the Bosavi has a built-in lithium polymer battery that sits inside a machined aluminum heat-sink that doubles as a reflector for the light. Its beam comes from a 110-lumen LED, which is bright enough for use while hiking or rolling in a city on a bike at night.

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Solar charge

Freschl’s project was self-funded and it “relied entirely on low cost tools such as open-source software, salvaged manufacturing equipment and community resources,” he wrote. Work on the headlamp began two years ago, and now this year after a successful Kickstarter campaign that raised more than $20,000 Freschl is looking at a manufacturing schedule that will start soon.

“Bosavi’s story isn’t just about a headlamp,” Freschl wrote me. “But it’s about a new way of creating a business — I have done everything on this project by myself, including the design, development, programming, sourcing, branding, web-site creation, videography, and photography.”

To see Freschl’s neat new headlamp concept, go to Or fund the startup via Kickstarter at this link. —Stephen Regenold

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Cord-pull electro generator charging the headlamp

Posted by T.C. Worley - 05/24/2012 09:13 PM

I love these kinds of start-ups. Kickstarter has launched a whole new generation of “idea” people and while some of them are dreamers, I love seeing the efforts and the go-get-it attitude. Best of luck, Dan!

Posted by Andy Robert - 10/12/2012 11:57 AM

That’s really a great and informative post. Keep up the good work.

Posted by Eddie - 10/15/2012 12:31 PM

I admire Freschl’s effort in the field of headlamp and also include all other sources with it. I really like this headlamp and it’s charging way. It feels like a modern age gadget. I appreciate your work and encourage you to continue your effort.

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