Hey everyone,
My meeting with TigerLight on 12/21 addressed some of these issues. Here's what we found out.
Because of the way the reflector is dampened on the TigerLight, the lenses will break if the flashlight is thrown onto a hard surface - like concrete. The reason it breaks is because the design of the flashlight allows lens will move very easily. This is true of the poly lenses as well. You can push on the lens and you'll see what I mean. This allows the lens to slam into the inside of the bezel when subjected to a sharp impact, causing the lens to break. A thicker lens will actually lessen this effect.
We were able to substantially help this by either doubling up the lens or removing the o-ring where the bezel meets the body. This tightened up the entire assembly and didn't allow the lens to impact the inside of the bezel as hard. After removing the o-ring, we were able to drop the light from about 10-15 feet without breakage (on concrete).
The solution? Not sure yet. I'm toying with the idea of some sort of shoulder washer to surround the lens - or maybe an o-ring. TL is interested in using these lenses, so I'm sure we'll come up with a durability retrofit.
There was no arguement about this - if you are planning on using your TL in a rugged environment and can't risk having a lens break becuase of an impact, stick with the poly. If you don't subject your light to impacts and like the idea of having your light be about 7 or 8% brighter, go with the UCL.
I'll keep everyone updated.
Chris
PS - we put a TL face-down on a desk for 5 minutes to heat the lens up and then shoved it into a bowl filled with snow. The result? Nothing - the lens stood up to this just fine. The fact theat the lens passes more light means it will stay cooler. No need to worry about thermal shock breakage.