There are workers doing this bypasses manually, some are skilled, some not. The Q8 even needs 4 bypasses. Just a question of minimizing warranty problems.
This is my thinking as well. I see no reason to demand they bypass the springs as long as they can handle the current, even if run with a single cell (if that option is going to be advertised with the light). If the springs do not melt in these conditions then I would just leave them alone.
From a manufacturing perspective double springs is the easier and cheaper option as well. That can simple be reflowed onto the PCB and needs no manual labor / skill.
In the OP we called for "Double springs with the smaller being Phosphor Bronze springs". I'm thinking we should stay with this approach - this was decided on way back.
Yep, I'm emailing a whole bunch this morn with our manufacturer contact about the prototype and where to go from here. There were a bunch of things done he wasn't aware, and was out of his control then. He just wanted to get the proto out to us in a rush as-is, and realizes there's a bunch of shortcomings. Things have changed over there since, so it seem we have a much better line of communication right now. If nothing else, this prototype has kicked this off -- all good.
750+ Woaw Woaaaaw Waaaaaarg g g!
Good job The Miller!
I hope the very noticeable interest in this project and the SRK style flashlight type will help motivate a better then decent manufacturing process and put it back into the glorious position it used to sit.