The SYNIOSBEAM - CFT90 recoil thrower






INTRODUCTION

The SyniosBeam skybeam is a high efficiency LED-based searchlight using a new design completely different from the previous two searchlights, the LightCannon and the OptoFire. This design consists of a backwards-firing Osram Synios LED combined with an 11 inch diameter precision reflector. With the higher intensity LED, redesigned optical system, and better cooling, this light is expected to surpass 12 million candela, the intensity of the very popular Maxabeam military searchlight. Extensive research and testing has led to a design that looks very different from a typical flashlight, however the portability and battery power will still classsify this searchlight as a flashlight, potentially making this the world’s farthest throwing LED flashlight if the expected performance is achieved.




WHY A THIRD VERSION?

This is the third long-distance LED searchlight that I am building, so you may be wondering what was not good enough in the first two. Here I will explain my reasoning. First of all, a large flaw of the previous designs was found when doing some beam collimation testing. When a template was placed in front of the light with small holes in it, it became very obvious how much chromatic aberration was occurring. Not only does this make the projected spot appear ugly, but the separation of colours could also be affecting the overall intensity of the beam. With some wavelengths bending more than others, it is possible that some light is missing the hotspot altogether and being wasted. This is a natural properly of the refraction of the glass, and even though (very expensive) options exist to counteract this, such as achromatic lenses, there will always be some difference between the angle of the red and blue wavelengths exiting the flashlight. The best solution for this problem is to use mirrors instead of lenses, since reflecting light will not cause any achromatic aberrations.

Another issue with the previous two designs is that it is difficult to continue improving them by using larger lenses. The 120mm OptoLife lenses found for the OptoFire project were the largest stocked aspherical lenses I could find on the market. To increase the candela further by using larger lenses would require custom made lenses, which would cost thousands of dollars rather than the tens or hundreds of dollars that stocked lenses cost. Not only that, but as the lenses need to be made of glass and are very thick, the weight would increase exponentially with larger diameters. This means that using large diameter lenses is both financially and practically unfeasible. The third issue with the previous aspheric lens designs is that the small light collection angle from the use of a lens means only a fraction of the LED’s luminous flux gets used and output by the flashlight. Even with a light recycling Wavien collar, only about 25% of light gets collimated into the beam. This means that the overall efficiency is much lower, and the lumens projected onto the targer are very low. The final problem is again to do with the use of lenses. When a lens is manufactured, not all of the front area is properly aspherized. Lenses will have a “clear aperture” specification stating what percentage of the diameter is actually properly machined and useful. Even if the lens is 90% or 95% clear aperture, there is still optic diameter being wasted, making the head of the flashlight larger than necessary and some light will not be properly collimated into the beam. On top of that, the surface for an aspheric lens is very complex to machine due to the equation that defines its slope. This means that to get a high quality asphere that collimates light very well, expensive machines and manufacturing processes need to be used, adding to the cost. Getting a perfect asphere on a lens is near impossible.

These are most of the down sides of the previous two designs, and the main reasons why I will be using a parabolic reflector for this next prototype. Below is a detailed comparison of six different light collimation methods considered for this project. Multiple-lens assemblies were omitted because they do not increase the candela over a single lens setup, they only increase the amount of lumens collected, which would make using a Wavien collar not an option.

Other than two down sides, no option for a Wavien collar and less spot sharpness, the rear-facing LED and parabolic reflector is clearly the best option for a large-diameter searchlight. Even though the first two have gotten very high candela, there is always a way to increase the numbers. The larger optic diameter, better LED, better cooling, the use of a reflector instead of a lens, and an overall better design makes me confident that this third prototype will surpass the previous two by huge amounts.




TABLE OF CONTENTS

1) Introduction - Pg.1
2) Why a Third Version? - Pg.1
3) Real World Applications - Pg.1
4) Theoretical Intensity and Other Specifications - Pg.1
5) Parts List - Pg.1
6) Budget - Pg.1
7) Prototype Revisions - Pg.2
8) Renders - Pg.2
9) Build Process - Pg.3
—— the reflectors
—— the waterblocks
—— waterjetting
—— electronics
—— more electronics
—— chassis
—— chassis finished
—— liquid cooling and first test
—— AR lens and outdoor beamshots
—— anodizing finished
—— initial testing
—— final assembly
10) Finished product pictures - Pg.7
11) Beamshots - Pg.7
12) Performance Results - Pg.9
13) CFT90 upgrade - Pg.12
14) Conclusion - Pg.12

Several people have asked me what is the use of these extremely long range flashlights. While furthering scientific research and personal learning is one of my goals, there are several real-world applications where this type of technology is used.


Architectural

Sometimes high intensity lights are used at the top of buildings as an architectural art piece. This beam of light is visible from many kilometres away and draws the attention of anyone looking up at the sky. One of the most well known examples of lighting used in architecture is the Luxor hotel, which has a several billion candlepower beam of light exiting from the top.


**Marine** ![](https://i.imgur.com/oCewG2p.jpg) Searchlights are very commonly seen on boats. The light helps navigate at night where rocks, islands, or a dock may not be well illuminated. Having a beam that can penetrate thick fog and humidity often found at sea is important to avoid collisions and to be seen by other ships, similar to how headlights on a car serve as an indication to other drivers about where you are.
**Search and rescue** ![](https://i.imgur.com/spYBffP.jpg) A very common use for searchlights is exactly that, search and rescue. When a person is missing or a disaster happens, first responders such as helicopters, ships, or land vehicles need to use very bright and long distance lights during the night time. Searches can last many days, and it is important for these rescue services to work around the clock, including during night or storm conditions.
**Defence** ![](https://i.imgur.com/wNypIZ1.jpg) Military and other defence applications also have a use for high powered searchlights. Searchlights can be used to spot enemies and reduce their visibility at the same time, or to find well hidden objects of interest during the night.
**Entertainment** ![](https://i.imgur.com/QrXy59c.jpg) Many different types of lights are used in the entertainment industry, one of the most common one being a ‘moving head’ light. Most commonly used in concerts and similar types of events, these lights can project an extremely bright and straight beam of light to create many unique visual effects.
**Inspection** ![](https://i.imgur.com/JBg439K.jpg) Certain types of maintenance and inspection jobs require working late hours or during the night, and a light which can easily illuminate objects at a far distance can help see. Not only that, but using a high intensity light at a closer distance can also give a much brighter spot, which can be useful in some cases.
**Monumental** ![](https://i.imgur.com/LJbZLTV.jpg) Similar to architectural lighting, searchlights are often used in “light monuments” consisting of extremely long vertical beams of light. These monuments, such as this one in iceland, are used to recognize and remember past events or people, and are a beautiful display of art that doesn’t have a very high cost.
**Surveillance** ![](https://i.imgur.com/HUGTgTA.jpg) Another application for searchlights is surveillance, especially in large expanses of land such as farms or prisons or any other area that needs to be occasionally searched at night. The search operation can be done at a safe and convenient distance at the searchlight without having to go very far to watch something. The use of binoculars is also very beneficial in this situation.
Finally, there is the undeniable bragging rights of holding the world record for the longest distance LED searchlight.

Several months of calculations and research were spent before beginning the physical construction of this project.
Equations for the calculations used can be found here: Reflector Type 2 (imperial)





Calculated Intensity (Mcd): 13.5
Calculated ANSI throw distance (km): 7.36
Calculated lumen output (lm): 775
Calculated spot diameter at 1km (m): 18.1
Calculated beam divergence (half angle degrees): 0.368


The flux and intensity values for the Synios LED were used from this test by a forum member
Due to a flaw in the testing of the Synios LED, it does not have the intensity we originally believed it did.
For this reason the Osram Oslon Black Flat is still the highest intensity LED at ~260cd/mm^2 and will be used for this project: [LED-Test] Osram Oslon Black Flat HWQP | Taschenlampen Forum
Unfortunately this means we will get a lower candela value than originally expected, however it will hopefully still exceed the throw of the maxabeam, and will also produce many more lumens than the synios LED did.
The name of the flashlight, however, will remain unchanged since the project has already progressed very far.

For this application, there is already another LED. It is already used by the military for lamps with a huge range. But the reference to the SLD laser disappeared. :person_facepalming:

You have my full attention Enderman. :slight_smile:

Finally a thread for this awesome project! I like your table comparing the different types of optics. Maybe you could also make one for different types of light sources :wink: (LED, HID, car HID, short-arc HID, Laser Phosphor, Halogen).

One thing I need to mention: be psychologically prepared for having to refocus the light 10, 20 times for hours or even days before you get the Candela value which you calculated! It already proved to be very difficult with my Project Excalibur light. The way you mount your LED should allow you to easily adjust the XY-position of your LED by 1/10th of a millimeter and the re-fastening it. You will probably have even more problems than the guy who built my light because you probably can’t do it inside?

Where is it used exactly?

Sounds impressive, looking forward to the build and first the parts list :slight_smile:

There are examples use here. Torches for the surveillance of the site SLDlaser removed. But they reach many kilometers 
 The first EDC offers” Acebeam”:http://www.acebeam.com/w10.

Looking forward to the build, nice work Enderman! :+1:

This is a very cool pic!

I agree.
Although Enderman’s light wont look anything like that with just 400 Lumens. :slight_smile:
It will be more laser like and the beam will be less visible.

I still think the Luminus CFT-90 is by far the best suited LED for this project.

Couldn’t agree more.

I have done research which suggests a laser phosphor system could get much higher than 300cd/mm^2, but have done no real world tests yet due to the high cost of lasers as well as the danger to the eye.
In the future I will definitely be exploring that option, but it was just not something I wanted to put into this light.
The goal for this was LED only :slight_smile:
I don’t really consider the laser phosphor technology an LED.

Thanks :smiley:

Great idea, I will work on a comparison of different lamps.
I also have to add some stuff to the optics comparison, stuff like multi-lens is missing.

I have designed a focusing system that is very precise, some spring-loaded screws can be turned to move the entire reflector forward and backwards by fractions of a millimeter :slight_smile:
You will see in the renders I post soon.

Thanks :slight_smile:

Yeah I was surprised when I heard about that W10 getting such high lux from such small diameter.
Laser+phosphor may be the future for high intensity!

Thanks! I have’t shows any of the real work yet since I want to post all of the preliminary stuff first like parts list and renders, but I have begun working on the physical thing.

If I can find a compact 30-50A driver that fits in the light I will mod it with a CFT90.
Currently the only drivers I have found that can do that run on 120/240VAC.
I do agree the beam brightness will be much more impressive even if I get less throw.
Worst case scenario I will mod it with an XHP70.2 and see how it performs :slight_smile:
For now I just need to get the thing built first haha

See here. Can be ordered here. You can choose the current (up to 40A).

Also, Lexel recently developed a 20A driver. You could ask him if it’s possible to make a 30A one or combine two of them.

Would this light be able to shed that amount of heat? after all the led needs to be in the beam path incl. the which includes the heat sink.

Maybe a heat pipe or water cooled solution to have less stuff in the beam and shed the heat at some place not affecting the beam.

Looking forward to the build.

A 6x6 array of XD16 dies would be perfect. ~28000 lumens and 80-100 cd/mm^2. :open_mouth:

BEAM SHOTS!! :partying_face:

Too large to fit inside the light, unfortunately.
I only have a few cubic inches of space due to how compact everything is inside.
When the light is finished, if there is no 30-40A driver out yet I will contact Lexel and see if he can custom build one for me.

You’re correct, LED cooling is very important but also hard to do when the LED is floating in front of the reflector and trying to block the least amount of light possible.
It is liquid cooled :slight_smile:
I’ll post the parts list tonight and renders tomorrow.
If I used the Synios DMLN31.SG I might have been able to get away with simply using heatpipes or directly attaching it to the aluminum, since it only uses 4W.
The higher temperature will probably reduce the candela though, even if it doesn’t overheat.
I might test it anyway though.

That’s not a lot of CD :frowning: but 28000 lumens in a spot does sound kinda cool :slight_smile:

Use your imagination :slight_smile: It isn’t even built yet! xD

Should be interesting :+1:

Not a lot of cd, but it should be a bit more than the sliced XHP70.2.

The XHP70.2 without slicing is almost at 100cd/mm^2 though?

At least near the peak of its performance.

I still think the CFT90 is the best choice for throw+lumen output :slight_smile: