The SYNIOSBEAM - CFT90 recoil thrower

You need to go into your account settings and enable high quality.
Then the images do not get lossy compression (they get very little compression, but it is lossless)
So for example one of my 4.5MB pics might be compressed to 4MB, but remain 6000x4000 and not lose any quality.
EDIT- actually if they are over 5MB they will get lossy compression, you’re right.

Also yes you can resize to whatever resolution you want individually, but that is a pain to do for many images so it is a lot easier to use the resizing during upload settings that RobertB posted an image of above.

BUILD PROCESS - final assembly


I had to buy a larger tube of thermal paste in order to heatsink the copper cooling coil to the flashlight bosy.





The top and bottom of the coil is glued with thermal epoxy to keep it from moving.
I decided to not glue the entire coil because it would make it impossible to remove if it needed to be replaced for any reason.





Once the coil was in I put the rest of the electronics and cooling loop inside the light.






The final components were the reflector and front glass.

FINISHED PRODUCT PICTURES

More pics coming soon, as well as beamshots!
No official performance measurements have been done yet, those are still to come.

I love how you still call this a “flashlight”. :+1: :+1: :+1:

Looking forward to beamshots and throw data!!

Cheers
Nico

I admire your skills in all things electronic and mechanical Enderman. Orsm effort. Thanks again for posting up. :+1: :beer:

That beast is a work of art. Congratulations on yet another fantastic build.

Beatiful

Haha thanks! I’m also looking forward to it :slight_smile:
Need to get my friend to help me out measuring at 400m distance!


Thanks guys :slight_smile:
Some beamshots coming later tonight, it is pretty insane.

BEAMSHOTS

10 000ft cloud cover
The pictures are not very clear because they were all handheld, I will be doing a better photoshoot using a tripod in the near future.

I can’t wait to see how impressive the beam is using a CFT90 :open_mouth: 5x more lumens will make a much more visible beam.

If the led you use has 450 lumen as I have read in your parts list,you mean that the CFT-90 has only 5X450=2250 lumens?I wait to put one in my GT, thinking that the CFT-90 will have at least 5000 lumens.
Am I waiting in vain,because it is unable to give those 5000?

The LED I originally planned to use in this light is actually not as good as we thought it was due to a measurement error.
I need to edit the parts list, sorry.
The LED being used is currently a black flat, with about 900-1000lm.

Looking at picture nbr 15 a friendly (and probably unnecessary) advise: watch out with aeroplanes nearby!
.
If you shine this -flashlight -searchlight at one, even accidentally, they will report it and you might get into trouble.
.
Apart from that: amazing light with amazing throu, congratulation of this terrific build!! :+1: :+1: :+1:

Cheers
Nico

WOW, is this for pleasure or for customer?
Outstanding work :slight_smile:

It’s not anywhere near as dangerous as a laser, but yeah I watch out for planes :slight_smile:

Both! That’s why I’m building two at the same time.
This one is mine and the second one I need to put together will have a CFT90.

a lot of work to get this driver done

here some pictures of the progress in cooperation with enderman

90 minutes work function block works

Upscaling to 8 circuits

a lot little things optimised

Central connecting pads added

Implementing inner layers for current conduction

Enderman wanted the connection on the back side, some minor improvements to inner layers and viases for curent transfer

After I saw this picture of mounting it I thought he is misunderstanding the colling concept with viases to the back side

So I told him to mount the driver with the back side to the case and we took thinner inductors to stay within 5mm thickness

enhaned the top and bottom ground connection as I removed the inner ground layer on a big parrt for LED+ paths

There are a ton of components on that thing…
wow
Amazing job!

The amount of ICs is just over the top! :wink:
How about the some status LEDs for the nerds? :stuck_out_tongue:

Lovely driver! Thanks for giving us a window into the design process, Lexel.

Enderman, great job on the light, and thanks for documenting it for us.

BTW, Vinh has shown his CFT-90 driver recently:

I have seen this as well, but the design seems not well cooled
He went a very easy way and simply bought a complete Constand Voltage module, externally PWMing it

Basically he put a 20A board from Mutara on top of a normal driver
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&ved=0ahUKEwiy1NPD3sbaAhXBLlAKHdamAD0QFggyMAE&url=https%3A%2F%2Fpower.murata.com%2Fdata%2Fpower%2Fokl2-t20-w12.pdf&usg=AOvVaw348cKN7GtTzFjlo9YErloo

He has practically all heat generating components on a slave board,
which is externally PWMing this with an external P-FET

I hope he is only PWMing low output levels with the external MOSFET to get Moonlight and get the higher Output regulated over the output voltage,
but still he is using a CV module for a CC operation which is not ideal

It uses P-FETs which are in general a lot less good than N-Types

My design has all heat generating FETs close to the edge and with at least 2 layers heat conducted to the outer diameter

1 Thank