Lightweight headlamp project

Flashlight Modding and DIY Parts
1

I am designing a headlamp for precision work.
The requirements are:

  1. 60K lux at 40cm distance
  2. dimmable
  3. zoomable
  4. lightweight

Here is the source of inspiration:

Here is the prototype built with a easy2led housing and GoPro parts:

The driver compartment:

Front view:

Resulting beamshot:

The current housing is too heavy, so I am designing a new one:

Currently I am using this Recom driver: RCD-24-1.20 Recom Power | Power Supplies - Board Mount | DigiKey
and a Cree XP-L HI
the result is only 30k lux at 1.2A

I have a bunch of various lenses and 30k lux is so far the best result. How can I improve this result?
I have ordered Osram Black top and will try it.

2

Looks great! Awesome project. :+1: :+1:

3

I’m with thijsco19 on this. :beer:

4

Moved the GoPro mount up

Added cooling fins in the rear

The circlip is not a good idea, I think.
The front lens will be held in place by a threaded ring, this way it will be possible to use different lenses and it will be possible to swap them.
Like in this housing: http://www.easy2led.com/index.php?main_page=product_info&cPath=65&products_id=181