Heres some pics of work in progress. I'm going to document some images of my aspheric headlamp here.
So far ive been using an aspheric headlamp for work which I had made about a year or two ago. The design goals were, in order
1) ZERO spill light
2) High output
3) Light weight
4) Aesthetic design (which comes with functional design IMO)
Came up with this
Over the year, I have modified the optics, gone through several emitter upgrades, and added the orange o-ring to fill in gaps from different optics. Referring to the original list up top.
1) Spill is quite aceptable
2) Output is only Just sufficient**, especially compared to commercial products (its more than bright enough on full, but thermally it cant maintain full (90 deg C at the emitter))
3) Definitely sufficiently light (13.5g all up including half the cable)
4) Aesthetics are simple enough.
It has the following shortfalls
1) THERMAL! it doesnt have enough surface area to cool, so it gets super hot. Running at reduced output is ok, but brightness isnt as high as desired.
2) Output is still too low. Optical inefficiency. I have 3 lenses in the light, they give a nice light with minimal chromatic aberration, but they just waste light.
So right now im making up a newer one which aims to address the issues
1) Thermal - increased surface area through incorporated fins
2) Output will be increased with a simpler single and larger convex lens with a shorter focal point. (however this lens seems to produce more chromatic aberration, and a projected image that changes more rapidly away from the focal distance (set to about 400mm)
3) weight will be increased. It already feels really heavy... :(
I've strategically positioned the part onto other torch parts around, it doesn't actually work, but woudn't that make a cute torch!!!