Hammerhead,
The diameter of a light is very important to me. This is in keeping with our motto, "lights that matter". A light is more likely to "matter" if it is easy to carry.
Diameter is one of the first things I specify with a new design. If I need to add volume, I would prefer to add it in length. The problem usually with a minimum diameter is the optics. If the optics are too small, efficiency and beam characteristics suffer.
The original design for the Arc4 (called the LS2, LSX and LS4 during development) was to be at least the same diameter of the LSH, which is 0.950" or smaller if possible. It is surprising what a mere 50 thousandths of an inch can do the "slimness" of a light.
Later in the design process however, I was persuaded to increase the diameter to increase the optical efficiency, allow more room for the electronics and have compatibility with all the 1 inch accessories on the market.
However in hindsight, those reasons didn't really pan out that big. In future designs therefore, I am more compelled to reduce diameter. I am upset that I didn't realize this sooner and that is the regret I referred to.
As far as a flashlight with a 5w emitter (Arc5?), I have yet to see an optics package that can smoothly and tightly focus a 5w emitter, efficiently and have a case diameter of less than 0.950". An EDC light must have range to its beam. I consulted with company here in Arizona that does optics for military and aerospace contracts. They told me the optics I wanted violated several laws of light propagation. /ubbthreads/images/graemlins/smile.gif
The Arc5 design is still in flux. My goal is to make it the best EDC available. This takes some effort though and I currently considering working my way to up it with some intermediate designs. That means the Arc5 may actually be called the Arc7 with the Arc5 and Arc6 being more powerful medium die models.
Small die
Arc-AAA
Arc-AA
Medium die
Arc-LS
Arc-LSL/H
Arc4
Arc5?
Arc6?
Large die
Arc7?
This is just an idea at this stage.. /ubbthreads/images/graemlins/smile.gif
One of the things that precipitated the possibility of intermediate designs is the realization that the medium dies designs still have some headroom to them. I came to realize that the electronics in the Arc4 are not nearly as efficient as they could be. Combine this with the problems in getting the large die optics into a small package and a 50+lumen medium die unit with a slim profile is look mighty Arc-like.
It would really help you to understand my design philosophy by ridding yourself the notion that the best light is the brightest. The best light is the one you have with you when you need it and it works well. As a result, building a big 5w flashlight is foreign to me. The only value I saw in the 5w emitter was making my single 123 cell designs brighter without making them larger. In fact, I was hoping the larger die would allow me to make an even smaller light because of the reduced heat produced. But because of the problems with the optics, EDC nirvana may be in the medium dies.
Also please understand what makes a small EDC brighter is not the wattage, it is the efficiency. This assumes the same battery and housing size and no laws of physics are broken. If you figured that out, my design goals will make a lot more sense.
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Why these intermediate models?
I thought the Arc4 has pushed the limits of light output for a single cell, sub 1 inch, medium die product. That is why I had originally planned to make my next EDC use a 5w emitter. The contractor I hired to design the power supply for the Arc4 told me that the kind of increased power I wanted was "impractical".
We now know of course that a more powerful and more efficient power supply will fit into this size package. We are now back to where we were 2 years ago. I am working on a single cell, medium die, high power EDC. The efficiency of this design is intended to be one of the best for its design parameters.
Now I would skip straight to the 5w emitter but I don't think everyone can afford such an expensive light and I am just not happy with the optics solutions we have seen to date. The 5w emitter may never produce the beam I want out of an EDC.
The test of time seems to indicate that my original design goals are probably the best EDC for Arc to produce. This platform will have the capability of using the more efficient LEDs coming down the pipe. Lumen output will steadily climb.
Peter