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Thread: Integrering reflector in light shell

  1. #1

    Default Integrering reflector in light shell

    Planning a new flashlight with an aluminum shell made in a CNC lathe. I was thinking about carving the actual reflector from the shell interior. What do you think about that? Has anyone done something similar or is it a bad idea?

  2. #2

    Default Re: Integrering reflector in light shell

    Only way I can that working is with a pill system, I think you'd be better off with a separate reflector and an integrated shelf.
    White wall hunting is not a very good indicator of a flashlight’s potential, not sure where it got it’s popularity. - DB Customs

  3. #3
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    archimedes's Avatar
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    Default Re: Integrering reflector in light shell

    Yes, some inexpensive older small flashlights have just used the raw aluminum from behind a 3mm or 5mm emitter as a "reflector" .

    I can't easily think of any examples using a power LED.

    If the surface polish gets damaged for any reason, replacement is certainly inconvenient, in that case.
    ... is the archimedes peak

  4. #4

    Default Re: Integrering reflector in light shell

    The front glass will be glued, so there will not be any way to change the reflector anyway.

  5. #5

    Default Re: Integrering reflector in light shell

    Quote Originally Posted by Ozythemandias View Post
    Only way I can that working is with a pill system, I think you'd be better off with a separate reflector and an integrated shelf.
    what do you mean with "pill" system?

  6. #6
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    Default Re: Integrering reflector in light shell

    He means a separate light engine "module" (often, but not invariably, threaded)
    ... is the archimedes peak

  7. #7

    Default Re: Integrering reflector in light shell

    Quote Originally Posted by archimedes View Post
    He means a separate light engine "module" (often, but not invariably, threaded)
    Yes.

    The downside of this is that the heat will often bottleneck at that junction of the pill to body. An integrated shelf sandwiched by the mcpcb and driver is more efficient when it comes to heat handling.
    White wall hunting is not a very good indicator of a flashlight’s potential, not sure where it got it’s popularity. - DB Customs

  8. #8
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    Default Re: Integrering reflector in light shell

    I've always thought electroless nickel would work pretty well if you got the surface finish really good, and found a good plater. In fact, EN on the whole light would be fantastic. Geometry of the reflector is pretty critical, though, especially if you're building a thrower. Plus, the design and heat flow issues above might steer you towards a separate reflector.

  9. #9

    Default Re: Integrering reflector in light shell

    Quote Originally Posted by Keitho View Post
    I've always thought electroless nickel would work pretty well if you got the surface finish really good, and found a good plater. In fact, EN on the whole light would be fantastic. Geometry of the reflector is pretty critical, though, especially if you're building a thrower. Plus, the design and heat flow issues above might steer you towards a separate reflector.
    Heat transfer is not an issue, I have already done test on prototypes that showed this was solved, reflector design is my biggest known issue.

  10. #10

    Default Re: Integrering reflector in light shell

    Quote Originally Posted by maxomolo View Post
    Heat transfer is not an issue, I have already done test on prototypes that showed this was solved, reflector design is my biggest known issue.
    What is this design accomplishing?
    White wall hunting is not a very good indicator of a flashlight’s potential, not sure where it got it’s popularity. - DB Customs

  11. #11

    Default Re: Integrering reflector in light shell

    Quote Originally Posted by Ozythemandias View Post
    What is this design accomplishing?
    Less parts.

  12. #12
    Flashaholic* fivemega's Avatar
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    Default Re: Integrering reflector in light shell

    Quote Originally Posted by maxomolo View Post
    Planning a new flashlight with an aluminum shell made in a CNC lathe. I was thinking about carving the actual reflector from the shell interior. What do you think about that? Has anyone done something similar or is it a bad idea?
    http://www.candlepowerforums.com/vb/...y-Fivemega-(2)

    http://www.candlepowerforums.com/vb/...er-by-FiveMega

    http://www.candlepowerforums.com/vb/...or-by-Fivemega

    http://www.candlepowerforums.com/vb/...ad-by-Fivemega

    Quote Originally Posted by Keitho View Post
    I've always thought electroless nickel would work pretty well if you got the surface finish really good, and found a good plater.
    No matter how well you do reflector nickel plating, chrome plating or gold plating, nothing will be even close to aluminizing.
    Chrome plated reflector can only reflect 60~70% of emmited light while aluminized reflector does more than 90%


    Quote Originally Posted by Ozythemandias View Post
    What is this design accomplishing?
    Less weight, less cost and much better heat management.
    Last edited by fivemega; 08-22-2017 at 05:48 PM.

  13. #13

    Default Re: Integrering reflector in light shell

    Awesome mods.
    What is the point of aluminizing if it is already made from aluminum?

  14. #14
    Flashaholic* fivemega's Avatar
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    Default Re: Integrering reflector in light shell

    Quote Originally Posted by maxomolo View Post
    What is the point of aluminizing if it is already made from aluminum?
    Aluminizing doesn't mean pure aluminum. It is a coating that shine much better than any metal and stays like that for very long time.

  15. #15
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    Default Re: Integrering reflector in light shell

    Moving this thread to Home Made and Modified Flashlights Discussion forum.

    Bill

  16. #16
    Flashaholic* DIWdiver's Avatar
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    Default Re: Integrering reflector in light shell

    Quote Originally Posted by fivemega View Post
    Aluminizing doesn't mean pure aluminum. It is a coating that shine much better than any metal and stays like that for very long time.
    Okay, so I spent a while on g00GlE and everything I see talks about pure aluminum. Can you say some more about how a reflector is aluminized?

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    Default Re: Integrering reflector in light shell

    It's kinda funny while reading the op I thought of fivemega. And who should stop by and respond?

    Anyway my two cents is to do a removable/replaceable bezel that is the reflector, like the version 2 deep mag reflector. This would also allow the use of an integrated shelf for the mcpcb and driver. But either way would be cool in my opinion. Whatever you decide keep us updated and have fun.

  18. #18
    Flashaholic* fivemega's Avatar
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    Default Re: Integrering reflector in light shell

    Quote Originally Posted by DIWdiver View Post
    Can you say some more about how a reflector is aluminized?
    Just google for Vacuum Metalizing.
    Lots of information there. You can also watch some videos in YouTube.

  19. #19
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    Default Re: Integrering reflector in light shell

    Any updates on this? I'm just interested to see what the OP comes up with.

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