Lookn good. Thanks for the update
Whoa, bling!
BlueSwordM you must have the patience of a saint to untangle all those springs.
Yeah, it takes a bit of time.
However, one way to untangle them all is just to mix them in the bag, then put them in another bag.
Actually works pretty well.
Those look great! :+1: … Looks like the “fun” begins pretty soon for you…… having to sort that tangle out. 
This, I have the 2000K E21A, more like 2300K in person, and I feel naturally sleepy with it on for a little while.
Related followup to my earlier post (follow along in maukka’s thread for discussion so we dont derail this one too much)
I ended up buying the cheapest spectrophotometer X-Rite makes (ColorMunki Photo / i1Studio) for $250 used but good condition on ebay. With just that investment I am able to get all the spectrum data needed for CCT/CRI/DUV and can make wavelength and CIE plots with entirely free software.
While it isn’t a self contained mobile device like what djozz has you can buy a $2 OTG cable and a $99 app that will get you “mobile” if you don’t want to use a laptop.
After having done this now I really wish we could do a BLF Arduino/Pi based spectrophotometer and lux meter. It doesn’t seem that complicated, the device outputs a decimal value for each wavelength and that’s it. The rest is just math equations using those numbers to get the rest. No special sauce/proprietary stuff needed.
@contactr, that’s nice. I’d love to get one.
@teacher, yeah, it’s gonna take some time to sort it all out.
Also, guys, I’ve discovered something interesting about electroplating in my research and testing.
Basically, you can do multi-layer plating.
With say a BeCu spring, you can do something like this to up performance significantly:
BeCu wire-Nickel plating-Copper plating(30-40um)-Silver plating(15-20um)
That would actually add a very nice boost to performance without increasing thickness at all.
That would be great for a Rev 3 spring.
Some very good news, some good news, slightly bad news.
Good news : the springs have arrived.
They’ve all been checked to be silver plated via a magnet test.
They also look amazing.
Very good news : the springs have very high conductivity, because not only are the springs silver plated, but also because I removed a coil from the large spring.
Overall, I’d say these are excellent springs. Onto the mechanical analysis :
So, guys, there’s a good reason why I wanted to keep the large springs at 5 coils.
Some data.
Nickel plated large spring: 13mm-12mm. 1mm loss. As expected.
Nickel plated small spring: 11mm-8,5mm. 2,5mm loss. As expected.
Silver plated large spring: 12mm-9,2mm. 2,8mm loss.
Silver plated small spring: 10,5mm-8,0mm. 2,5mm loss. As expected.
You see, when I made the calculations for the 1st spring, I accounted for both yield strength and compression ratio (min height it goes down to). Being less conical than the 2nd gen spring, it had no problem with this.
When I made the calculations for the silver plated large spring, what I did not take into account was the conical shape of the springs, which allowed for more overall compression, which means higher tension, which equals higher force applied, and more room for plastic deformation… You can guess that I’m happy with the large spring, but not ecstatic.
All in all though, I’m still very happy with my springs.
For the 3rd gen springs, I’m just going to keep the same 5 coil design for all of the springs, but spruce up for some multi-layer electroplating.
All good news to me. It’s basically a more universal Emisar spring and I have a lot more uses for such.
Is the part that has not been crossed out the “slightly bad news”??
Maybe this has already been covered, but up above you said : “So, guys, there’s a good reason why I wanted to keep the large springs at 5 coils.”.
If you “wanted to keep it at 5 coils”, why was it changed??
Just curious….
Well, for 2 reasons:
1. Better conductivity because removing 1 coil makes it about 20-25% better.
2. More room for compression.
The thing I did not take into consideration is that I changed the top diameter from 7mm to 6mm.
That meant that the spring could fully compress, meaning it was subject to more force, etc.
Meaning there was more room for plastic deformation, and thus, the 2,8mm instead of 1,0mm.
TLDR: I didn’t have confidence in my own abilities to design a spring, but I already had the results, and I was actually competent knowing about this. I really should’ve believed in my abilities.
Rather than listening to suggestions about even higher conductivity by removing a coil, I should’ve just kept on my original train of thought on how to spec the springs.
Basically, I should’ve just made the top diameter smaller 
/\ … OK, thanks for the info BSM. 
Yeah, believe in yourself; I’m thinking you are very competent!! 
So, plastic deformation is almost 3x what it was in the first generation large spring. That’s not good. But it depends on the installation whether it will be a deal breaker or not. In some lights, short cells could be a real problem. In other lights, it might be okay. Do the springs still stack pretty well? I wonder if the large spring with a small one stacked inside it will still deform as much as the large spring by itself does.
They actually stack even better than the 1st gen.
Would you test the plastic deformation while stacked and see if it is still 2.8mm deep?
Well, you’re right!
By spreading the force over a large surface area, we are reducing the compression force/area for the spring, and the deformation isn’t as bad.
Overall though, while it’s the 2nd best spring electrically, the 2nd gen large spring is worse mechanically than the 1st gen one.
However, this is just my fault on my part for not believing my initial calculations.
And it’s not all bad news though! The electrical conductivity is off the charts, and with the lower resistance, we went from 20A+ for a dual spring setup, to 24A+. So even better
Finally, I’ve prepped all of the orders that only have the springs+3500k LEDs. The orders with 3000k will be completed on Tuesday, and shipped on Wednesday.
I will be receiving the SST-20 3000k LEDs on Tuesday, so I’ll have to wait until then.
Also, I’ve discovered something that could actually lower the price of the springs while getting the same performance!
It’s called triple layer plating. Will talk about it soon enough.
For now, sorry for the spoiler, but here are the 3rd gen specs, especially since this 2nd gen will go by extremely quickly this time around, since I’ve got everything I need and the material necessary.
Small spring:
Material: Beryllium Copper C17530 38% IACS
Spring upper diameter: 4,25mm
Spring base diameter: 5,75mm
Spring thickness: 0,8mm
Spring height: 10,5mm
Total number of coils: 5
Plating: Silver electroplating
Large spring:
Material: Beryllium Copper C17530 38% IACS
Spring upper diameter: 6mm
Spring base diameter: 9mm
Spring thickness: 1,0mm
Spring height: 13mm
Total number of coils: 5
Plating: Silver electroplating or triple layered nickel plating(nickel-copper-nickel)
Hi Blue, what is the reason that you represent the performance of your springs in current (A) instead of resistance (Ohm)?, since the current is dependent on not just the spring but also the voltage over the spring. And how would I calculate the resistance of a say 24A Blue spring?
Well, let’s say the nickel plated springs have a resistance of 10mOhms each(technically, it’s lower, but I like round numbers).
In a dual spring setup, that would mean they have a resistance of 5mOhms.
The max power dissipation is 2,2W.
So: 0,0005Ohms*20A = 2,00W.
With the silver plated springs, it should be lower.
However, I didn’t have the time to measure it yesterday, so I’ll do it today.
Edit: Tomorrow actually. Got some work to do today. I have to cover someone at work for being sick.
@djozz, the reason I’m saying amps instead of mOhms is because for some reason, people have more ease with amperage measurements rather than resistance measurements.