ROP-HI bulb solder blob melting (and plastic bulb holder)

[WildChild]

What can cause an overheating that melt the solder blob of the bulb? The plastic bulb holder also became textured and slightly deformed on the edge near the bulb and the spring isn't strong enough to push the holder completely anymore but the holder moves enough so I can focus the bulb correctly.

I use the ROP-HI bulb in a 2D Maglite with 6AA (Eneloop) in a fivemega adapter. I ran it a few times for 20 minutes (complete batteries life), with cooling time between runs.

 

[Icebreak]

I have a possible answer for you in the last post of the Race To Failure thread.

Short answer is I now believe QA on the potting might be the issue.