Project EMERALD log! (SWM F30R mod)

joined the audience :-)

The LZ1 comes in 365nm as well, but those Luxeons are so small and elegant, and go as low as 380nm as well.

This morning’s layout progress. Got the weird tri-lobe board edge in and did some component grouping:

started the main & daughter boards. got the outlines set and basic component arrangement established. here’s the current challenge: locating the 4 pins that pass from main up to daughter while avoiding impeding on the space for battery contacts and the shelf (exposed case material, must be unmasked copper) regions.

I can recommend Mill-max pins for PCB interconnects. They'll give you the cleanest connection. They also have an insanely large range...

https://www.mill-max.com/product_finder

They do through hole, surface mount, press-fit, solder-fit and so on. They'll have something you can use I'm positive of it.

Woohoo, finally got the shipping notice for mine (added stuff holding the shipment up). Should be here Wednesday. Think I’ll go ahead and do a review on mine before I tear it apart.

Got everything fully routed. The daughter board looks like it’s ready to order. The main board has everything connected, but I still don’t like the look of it… may need more work

work of art!

Love the sweeping turns of the traces on the right…beautiful!

Did you make a round polygon pour?

“Ratsnest: nothing to do”. Beautiful, I bet it even passes DRC huh.

I really like all the extra copper pour on the daughter board. I’ve started doing that too, I like the finished look better plus the extra heat sinking it provides.

The trick is to do a big polygon around everything that’s not any particular shape. Then when you have a circular board edge, the pour will automatically isolate from it by whatever distance you set in DRC and it matches the shape exactly

Will it isolate itself inside the milling layer?

Sweet…great to know…thanks a ton tterev3

main board is almost there:

finally done, and ordered!

Have fun putting that together!

Wow nice.

My F30R got here today!

Nice. With a comment from Matt like he did this must be a challenge. To me it would be an impossibility.

checkbook is ready, not sure there is enough in it though :_(

I spent a really long time looking at the ring of LEDs, trying to come up with some way to put TIRs or small reflectors in there and still get heatsinking and still make the light possible to assemble, and I couldn’t come up with anything. So I gave up on having nice beams and made this LED board that will fit right inside the aluminum ring with the 12 holes in it. The ring will provide heatsinking and keep assembly easy, and it has cone shapes machined in that will form very rudimentary reflectors. The beams will be very wide unfortunately, but they shouldn’t be ugly. There are 3 of each of the primary colors (spaced evenly so they won’t be off center) and single emitters for 380nm, 405nm, and 850nm. I used XQ-sized components for all so that they’d fit easily into the existing holes. Colors are XQ-E, UV are Lux UV, and the IR is an Osram SFH 4710 which appears to be almost the same package as the Lux UV

What if I turned a spacer to fill the gap between the bottom of this board and the pill / light engine housing then polished each individual “reflector” or better yet (tho expenses) had it electroplated?