Greetings,
I have been a firearm designer for many years; which I take great pride in delivering innovative solutions. Recently, LED flashlights have caught my attention. I am amazed how much I really enjoy learning about this industry.
I have my heart set on designing new line-up of lights that will appeal to the greatest audience. My design ethos has been lightweight, modular, and true user benefit. Please point me in the right direction. Reflector? Optical lens? Batteries? Modes/Functions? LED emitters, Lumen OTF range needs? Adjustable focus? Throw? ETC.....
Please advise! Please be serious in your comments.
I am no expert but I think Carbon fiber or maybe even Delrin would be great to make a flashlight tube from, maybe just as strong as Aluminum if it was made thick enough, what do you guys think?
One reason LED lights are made from aluminum is that it helps to conduct heat away from the LED and vent it to atmosphere. High-powered LED lights do generate quite a bit of heat. If you make the flashlight body entirely of carbon fiber or Delrin it probably won't be able to heatsink the heat as efficiently as aluminum.
You could still have an aluminum head, possibly with heatsink fins to accompany your plastic body, but this limits the amount of heatsinking available compared to a light built entirely from aluminum. You'll either end up with a light that is bigger and bulkier than comparable all-aluminum lights, or one that has lower output that doesn't drive the LED very hard.
Carbon fiber is a great dissipator of heat. However, resin is an insulator. I have a unique resin that supports dissipating the heat.
We have built carbon fiber wrapped barrels that go to 500 degrees F with no problem and you can touch the barrel within minutes. I am sure that carbon will be just fine for the light.
With carbon fiber you can make unique shapes with very thin walls......and still be stronger than aluminum. You guys are really getting me excited with this feedback. First design is well on its way. I'll need beta testers soon.
Carbon fiber is a great dissipator of heat. However, resin is an insulator. I have a unique resin that supports dissipating the heat.
We have built carbon fiber wrapped barrels that go to 500 degrees F with no problem and you can touch the barrel within minutes. I am sure that carbon will be just fine for the light.
With carbon fiber you can make unique shapes with very thin walls......and still be stronger than aluminum. You guys are really getting me excited with this feedback. First design is well on its way. I'll need beta testers soon.
Thank you for all the help. I am working on many of the details suggested.
i am writing and programming the IC on my driver with an Aduino board. I am trying to figure out how to be able to do this function in a simplistic way at user level......big challenge.
6) There is really no need to make the light focusable. Most good lights come with a proper focus setup right from the factory.
OH YES, I love my Ledlenser M1 EDC. Focusing makes a light lightweight, you have much more throw then you would otherwise have with such a small light.
PS: becoming a flashoholic I already ordered a ZL SC600. But I still think, focusable lights have their own merits...
To the original poster: For the light that you are designing... how do you envision it being used?
Is it meant to be a tactical light meant for law-enforcement use?
Is it meant to be a weapon light?
Is it meant to be a pocket EDC (EveryDay Carry) for civilian use?
Is it meant primarily for short range use or do you want it to have throw for seeing things at long range?
How important is it to have good flood and/or throw?
How big do you want the light to be?
Do you want it to be very reliable with long runtimes?
Do you want it to be a "pocket rocket" capable of very output at short runtimes? (but also with lower modes for longer runtimes)
Do you want it to be a general purpose light suitable for everything even if it doesn't excel at anything?
I think we'll be able to offer much more useful and focused suggestions if we know what you want your new light to do?
Thank you for all the help. I am working on many of the details suggested.
i am writing and programming the IC on my driver with an Aduino board. I am trying to figure out how to be able to do this function in a simplistic way at user level......big challenge.
To the original poster: For the light that you are designing... how do you envision it being used?
Is it meant to be a tactical light meant for law-enforcement use?
Is it meant to be a weapon light?
Is it meant to be a pocket EDC (EveryDay Carry) for civilian use?
Is it meant primarily for short range use or do you want it to have throw for seeing things at long range?
How important is it to have good flood and/or throw?
How big do you want the light to be?
Do you want it to be very reliable with long runtimes?
Do you want it to be a "pocket rocket" capable of very output at short runtimes? (but also with lower modes for longer runtimes)
Do you want it to be a general purpose light suitable for everything even if it doesn't excel at anything?
I think we'll be able to offer much more useful and focused suggestions if we know what you want your new light to do?