Building the perfect medical penlight

Flashlight Modding and DIY Parts
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Check out the Nitecore MT06MD.
It is a high Cre medical flashlight, that I personally use and recommend. It doesn’t have a well defined hotspot, which makes medium mode great for looking in the mouth and pharynx. It has low, medium, and high modes in that order, which I like, so that I don’t ever accidentally “blind” a patient, as I begin my exam. However, I do wish, the low mode at 4 lumens was a bit lower.

Lumintop also makes a highly regarded IPY365 hi Cre penlight. There is little need to modify it. It starts in medium mode, then low, and finally high. Its low mode is 1.5 lumens, which is useful when checking extra occular movements. (You will have patients squinting with 4 lumens. You will seldom use high mode with either light.)

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NEXTORCH DR.K3

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Not as nicely finished as the IYP365 but something like the Gerber Foreman with a Yuji swap might be nice. When I was in the field I just used a Solarforce Z1 and put up with the cold white. Had a nice low moonlight at least. Now that I’m inside I just use the wall mounted ottoscope.

If I went back into EMS I’d go with something like the Eagtac D25C with the 219. Or swap an SST-20 into your choice of host originally equipped with the XPG/2.

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Another med student here. Did you consider using Convoy S2 as host? I’m investigating on building the perfect med-light myself.

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Wouldn’t an S2 be way thicker than a penlight?

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Yeah, I don’t think an S2 is going to fit well in the chest pocket of a lab coat.

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This is a great project! I really like the idea for a good rendering penlight.

Have you though about bringing out a second version with a 485-500Nm Blue LED, this is very useful for using with fluorescing dye for checking eyes ( I had a doctor friend ask me to find a blue pen light for eye exams, ended up with a blue LED Niteore tube which works well).

The ones available on medical supplies websites are usually incandescent with a terrible blue filter.

This is the Nitecore Tube Blue:

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This is a brilliant idea, he can use a 18350 tube, and a diffused lens, with maybe 1x or 2x 7135 chips. Wouldn't be too hard, the SST40 sounds like a great led for it as well.

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Its a shame you destroyed the reflector. The solution was to replace the glass with a frosted glass or sticking a frosted film.

For the LED : SST20 4000k LED This is a good LED with 95 CRI not too warm and the 10mm star will fit the light. Its easy to replace but you will need a little thermal paste for good heat contact.

The no memory driver is positive because you always know what mode the light will turn on. The IYP 365 is an excellent light.

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I gave an IYP365 219c to a Physician friend of mine and he loves it.

It looks like Lumintop has discontinued the IYP365, and has the IYP25 now. No idea how the modes work, but medium is now 70lm instead of 40lm. It’s two AA’s now, plus they added a friggin strobe for some stupid reason. They also have the Tool AA which is the exact same thing as the IYP25, except it looks like a tool instead of an IYP.

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Please, please, make it autoclave-friendly.

Doctors spread diseases: Health care professionals' neckties as a source of transmission of bacteria to patients: a systematic review - PMC

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Ok, so I’ve actually started to spend some time in ER hell. :slight_smile: Most doctors are cheap/lazy so they’re just using friggin mobiles as flashlights. But I had some parts at home and is pretty satisfied with my result so far. As host I’m using a Convoy S2, led is xp-g3 4000k and driver is 4x7135. Modes are 11, 40, 120 and 255. So basically pupillary light reflex, ENT (ear-nose-throat), body exam and full mode when you need it. Beam had rings and crap in it but I solved it by sanding the lens a bit on the outside. Now the beam is without rings and evenly washed out. Will se if I will try some other hosts too? Don’t got any other small hosts at home right now, only S2.

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I’ve got several and the CRI on both emitters is ABYSMAL. Like 60 tops, don’t remember exactly, it’s been a while since I measured. Modification would be required, probably fitting Yuji or similar 5mm emitters and there’s no way to disassemble the light nondestructively since it’s glued from both sides. Also the tube is super thin (you won’t crush it between your fingers but if you hit a doorframe with this light in your pocket, it will crush and bend, tested).

I recommend against this.

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+1 for the Nitecore.

I gave my nephew, who is a Dr.; one of these along with some Eneloops & a charger.
He loves it.
He does not Autoclave it however. :wink:

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I asked Simon from Convoy about this kind of light so I hope he is seeing this

I'll give some ideas of my version of the perfect medical light if you guys are willing to chime in please do

*English is not my first language so please exercise your tolerance and correct me politely

1- Stainless steel

(justification: it is the preferred material for medical instrumentation for it's resistance to disinfection with alcohol or other disinfecting agents)

2- Waterproof not just resistant

(doesn't have to be certified, just tested and guaranteed by the maker - It has to resist washing it thoroughly after some kid vomited over it, or when it fell over spilled blood... don't ask)

2.1- A mostly smooth surface

(no place for things to cling on, because every bodily fluid you can think of will eventually have contact with it, we usually use latex or nitrile gloves and don`t move that much so just can`t be too slippery with those even wet)

3- A strong deep carry clip so not snag on things avoiding the fall in the first place,

4- A small flat area for engraving your name (could even be in the clip)

5- High CRI neutral white - nichia 219B or something similar, preferably floody with no hot spot (it can't be warm or cool so not to alter perception of color)

6- Tail click activation and a quality button that keeps water out and a decent good click (something like the metal one in the S2+)

7- Only 3 modes always starting on low, about 1 lumen, 3 at most

- low for pupils

- medium for small lesions, mouth, ears, noses and hum… other holes

- high for bigger lesions like rashes, cuts and bruises… and general use in life of needed, I find that around 200 lumens at most is enough

8- Low self discharge

9- Size comparable to a Bic pen without the cap or even a little shorter

10 - Not too expensive I`d suggest $20 to $30 as a sweet spot

Extras perhaps some available separately

- A package that reflects the quality of the light (initially a plastic pen case or a good laser pen case could be adapted to hold the penlight two extra AAA batteries and spare o'rings or any spare part you need to keep it working)

- A discrete headband to use it without hands (could be like the Convoy H1 band adapted, could be black with no reflective material, just to hold the penlight on the side of the head. usually I use a rubber band and a face shield so a better solution is welcome)

- A bundle with a 2 bay charger and 2 or even better 4 good quality NiMH batteries

- Later a stainless steel case could be added

If I think of anything else should I edit this post or make a new one? Any suggestions ?

@atomix? What do you think?

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[quote=korpzgrinda] Yeah, I don't think an S2 is going to fit well in the chest pocket of a lab coat. [/quote]

Yep it doesn't, and the T2 feels weird because it's too short, I use them both in work, the T2 with nichia 219C e S2+ with nichia 219B, since COVID-19 we are mostly using Scrubs so even smaller chest pockets, my solution was to use the optional stainless steel deep pocket clip sold in Convoy Store, the same fit both luckily and usually I carry them in my pants pocket, T2 has been there for six months and I clean it every time I use it, alcohol, other disinfectant agents, water and soap, I'm surprised by how well it handled the abuse, of course I'm careful and always check the seals but little to no oxidation, no water ingress this long is remarkable. Hope Simon makes a penlight for us in the future

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I`d suggest going with nichia 219B over the 219C (B in my experience was better for red/rosy colors evaluating anemia, bruises and hydration)

I used a S2+ with nichia 219B (Simon sells them)
https://pt.aliexpress.com/item/1005003110016944.html?spm=a2g0o.store_pc_allProduct.8148356.11.3b8e3f16DqeJGd

and installed this clip
https://pt.aliexpress.com/item/2049685616.html?spm=a2g0o.store_pc_allProduct.8148356.4.31b823632Ph5vE

But now there are versions of the T2, T3 and H2 with the same LED
H2 is 90º but has USB-C internal charging so for practicality it could be an advantage although with less resistance to water

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I recommend Stainless Steel type 1.4404 / 316L mirror polished and gap-free sealing design like used in the pharmaceutical industry.

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@ Renato
Did Simon respond to your thoughts about a lower level light?
My personal need is not for medical purposes but with similar requirements. Emphasis at lower levels;
two modes at 5-22 lumens and another at 120-180 luments. CRI > 90, warm temps 4000k, 5-6" length, Memory function. Start at low. thx.

1 Thank
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Hi Johnnie, unfortunately he didn’t show much interest, who knows maybe if more people ask him for a similar light.
I’m sure he’s got a lot of projects so I understand low volume specialty lights go to the bottom of the list.
Thanks for your interest, it’s nice to know

1 Thank