new flashlight design

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pointermachineworks
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new flashlight design

Hi guys first time posting, I am currently working on developing a flashlight and would love some input on components that you guys would recommend. The basic design of the light is a side by side 14500 set up parallel, rectangular body and I’m trying to keep it compact as possible. the light will be a modular design with a space for mounting accessories like a pocket clip and flush adaptors for keymod and mlok for weapons mounting. My head is spinning with all the different styles of drop ins that i have been looking at trying to get dimensions, the things i need help with are:

1. I would like to find a drop in for the led that is complete with the driver preferably in a brass pill that screws in from the front but is as small of a diameter as possible. from my research it looks like the smallest is those meant for a convoy s2 at 21.8mm. is there something smaller that is widely available or is that about it? not looking for insane output or anything crazy either, just simple and crowd pleasing.

2 The tail switch, i would like to have a metal button that screws in from the outside, i like the buttons that thrunite has on their lights but cant find any like it, is there a small metal screw in button that can be easily obtained?

Overall I’m looking to build a platform that has support already so that the lights could be easily modified and customized as well as make it easy for me to obtain the components to build them.

raccoon city
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It's nice of you to join us, pointermachineworks!

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Ironhorse
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Have a look at the Frelux Synergy 2.

pointermachineworks
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I have seen the Frelux lights, I like them but I have a different design in mind. As soon as i can work out the dimensions of my components i will be more than happy to share my models.

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Welcome to BLF pointermachineworks!

Seems an interesting idea, although I’m not fully conceptualizing it yet.
About the screw in buttons, you have those used in the Convoys with metal button.
I bought 2 here:
https://www.aliexpress.com/item/32834352871.html

As for the pills, ready to use, I guess those are the smaller available, and take 17mm drivers.
You have smaller ones, but not in retail, as far as I know.

redsuns
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Welcome! Interesting concept you’re looking to design.

pc_light
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Welcome Pointermachineworks.

Lumintop offers a version of the Tool AA, they refer to as the “Tool AA 2.0 HM Homemade EDC Flashlight Kit” that includes a modular LED and Driver drop-on of a sort. It’s definitely smaller than an S2.

Seeking the light.

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How about making the pill yourself? Mountain Electronics sells 15mm FET+1 driver, so you could have a small but powerful solution.

Smile, you cannot kill them all.

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> The basic design of the light is a side by side 14500 set up parallel

here is one vendors opinion about using Two Batteries

we STRONGLY ADVISE AGAINST THEIR USE. Catastrophic failure can occur when one of the two cells is not functioning correctly, causing thermal runaway in the other cell. There is a significant risk of fire and/or explosion when using two cells.

pinkpanda3310
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jon_slider wrote:
> The basic design of the light is a side by side 14500 set up parallel

here is one vendors opinion about using Two Batteries

we STRONGLY ADVISE AGAINST THEIR USE. Catastrophic failure can occur when one of the two cells is not functioning correctly, causing thermal runaway in the other cell. There is a significant risk of fire and/or explosion when using two cells.


Your link goes to a light that takes 2 cells in series.

 

jon_slider
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oops,

In Parallel does not have the risks of In Series
thank you PinkPanda

@pointermachineworks, I hope it turns out to be an awesome Two Parallel Cell Light Smile

I hear the AA/14500 Synergy is Two Parallel Cell too

good luck with the project
post pictures Smile

PinkPanda is very savvy about building lights.. hopefully will be able to offer you more useful advice, than I have so far.

Welcome to BLF

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Don't forget to make a 2x 18650 version at the same time .Seems like if it's a good design then either downsizing it and or upsizing it makes good sense .

I think a slide snap in mount for a bike light may give it some extra appeal as well as open up another possible market .

 

2xAA side by side done right has always been a bit elusive. yeah it's easy to do it if it's titanium and  the light costs an arm and a leg .

 The old school plastic lights ought to prove it can be done right .

       καὶ τὸ φῶς ἐν τῇ σκοτίᾳ φαίνει καὶ ἡ σκοτία αὐτὸ οὐ κατέλαβεν

                            

       Dc-fix diffuser film  >…  http://budgetlightforum.com/node/42208

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Welcome to BLF pointermachineworks! Good luck with your flashlight design and looking forward to updates.

I’d rather use my flashlight around the house than turn on the lights.

pointermachineworks
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Thanks everyone, looks like I am going to have to make the pills my self. I emailed mtnelectronics and am waiting to hear back about some of there smaller drivers. I started out wanting to use somewhat standard parts but am no going to make nearly every component in house so that i do not have to settle. the design is changing by the second but as soon as i have it a little closer i will be sure to share.

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No idea what size (min/max) you want for pills, but czech out fastttech.com first, as they got assloads of pills in all sorts of diameters/heights.

I got like 3 different types of brass pills that fit C8s to replace the crappy featherweight Al pills that came-with.

Pickin’ is less than it used to be, but…

https://www.fasttech.com/category/1616/flashlight-diy-parts-miscellaneou...

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pointermachineworks
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Thanks for the input everyone, Im moving along with my design and have decided to change the button and that is going to change most of my components. I want to go to an electronic button, the nature of my design just isn’t lending its self to a clicky/ latching button. Now i need a driver capable of running on an electronic/ momentary button with the lowest parasitic draw possible. I see mtnelectronics has a qlite driver that can run this type of switch, any other recommendations? looking to use a cree xml2 emitter. Also any sources of good electronic buttons? They are extremely hard to find.

pinkpanda3310
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I get the impression this is a huge learning experience for you Grad

 

pointermachineworks
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It most certainly is. Im figuring things out the best I can though, sourcing components is seeming to be the hardest part as none of the parts are made in the us, they are never properly represented on line and their availability is spotty.

pinkpanda3310
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I was going to suggest contacting TexasLumens but it looks like they no longer have any Website. I don’t know if the business closed down…???

 

pointermachineworks
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What im looking for in a button is really just the outside metal cap/retainer that screws in on side button lights. I can set up my own tactile switch underneath i just need a screw in metal cover/button.

pinkpanda3310
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The only thing that springs to mind is the convoy metal button which is not US made, of course.

Unlike rubber boots, metal buttons are usually a proprietary item on hosts. So there is very little available.

It kinda sounds to me like you are trying to piece together a ‘new flashlight design’ from existing available parts. For a tubular host that’s almost possible but for a side by side cell light that sounds like an impossibility. Or do i have that wrong… are you having a new host produced at a local machine shop?

 

Lightbringer
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Maybe get a metal switch for a Convoy S2+. Screw-in design…

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Lightbringer
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Dee-oh! Beat me by seconds…

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pinkpanda3310
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I beat you.. did i win..?? What’s my prize!!?? Cool

 

pointermachineworks
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I’m looking into those convoy buttons, the lead time in then isn’t great and it would be nice to have something in my hand quickly to know if it won’t work. I’m designing a side by side light from the ground up to hopefully produce and really at this point the only thing I’m not machining my self is the button but I’m thinking I will have to make that as well. Something like a piston in a sleeve with o rings or a similar design to the s2 metal buttons with a silicone boot only more flush and have it interface with a tactile micro switch. I’m trying to keep it as compact as possible.

pinkpanda3310
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DQG Tiny did some pretty small side switch assemblies. Some had a rubber boot, some had a metal button but all had a press fit retainer. I’m guessing that will save you a little bit of machine time if you press fit rather than thread.

 

pointermachineworks
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Thanks again for all the suggestions, its taken me a few months but I finally think I have nailed my design and what to see what everyone thinks.

Hopefully the images come through, my first time trying to post them.

The design is a 2 piece light that is brought together by the thumbwheel in the center. It takes 2 14500 cells run in parallel and will run on only one in a pinch. Right now i am building them with the Qlite momentary switch driver from mtnelectronics but am open to suggestions if someone knows of a driver under 18mm diameter that can run both aa/ 14500 but i haven’t been able to find one. I have designed the head to accept 20mm carclo optics and i will be offering both in single xml2 and triple xp-e2 configurations. The “guts” of the light are my custom made pill that holds the Led, driver with momentary switch attached that can be changed by unscrewing the front bezel allowing you to easily go between different led configurations by putting in a new pill/lens.
I am machining everything my self including the button that is located on the bottom of the light toward the front. The location of the button makes the light very versatile, lending its self to many different hand positions. The slot running between the batteries is a mounting point for accessories including the pocket clip, which can be loosened and slid higher or lower, Mlok and keymod weapons mounting adapters which will be flush to the rail, and a magnet to come later.
The weight is around 5oz without batteries, 4.15 inches long, 1.65 inches tall, .8 inches wide at the body and .96 inches at the swell on the head.
I hope to have a completed final version completed this week and i will share some photos as soon as I can

pinkpanda3310
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Pretty speccy looking light Cool

 

wle
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pinkpanda3310 wrote:
DQG Tiny did some pretty small side switch assemblies. Some had a rubber boot, some had a metal button but all had a press fit retainer. I’m guessing that will save you a little bit of machine time if you press fit rather than thread.

DQG had some TERRIBLE versions of side switches, though they were small, they broke very soon.

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wle
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it;s different but i would expect it not to sell to the ‘pocketing EDC’ market – it is too thick and heavy.

not familiar with lights that go on guns, maybe small and light do not matter to them.

just saying.

"You never have the wind with you - it's either against you, or you're having a good day."
    Daniel Behrman, "The Man Who Loved Bicycles".
It never gets easy, you just go faster.   
-Greg Lemond.
       ,ø¤º°`°º¤ø¸,ø¤º°`°º¤ø¸,ø¤º°`°º¤ø¸

jon_slider
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wle wrote:
i would expect it not to sell

beg to differ, it is titanium and made in USA, it will certainly sell

here is a similar two AA that weighs 115 grams and sells out at $250, in aluminium

maukka wrote:

here is a Spy007, USA made dual cell Ti $2,700:

the site http://www.coolfall.com/p007.html does not say what it weighs, nor what LED it uses… and there are no beam photos.. Im guessing the people who can afford it, dont care… (if I have to ask, I cant afford it)

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