32mm diameter copper boards: testing the water

Yes, it’s X9, excellent flashlight :wink:

btw, is it only me or someone else thought that having 7xXP-G(2) R5 on
32mm base would be very interesting :bigsmile: something like scaru’s bazuka
but wiht XP-G’s!!!

P.S. I really hate situation when something cost for example 4-5-6$ and shipping to me is like 40-70$
so the led could cost 3$ (excellent price if you ask me) but if shipping is 200%/piece then I am off :confused:

Just mod'ed an X9 for someone, reflowed a U3 1C and put in a KD V2 driver at 3.8A - wow, what a difference in that thing! Love the host. Ordered the look-alike from WallBuys on the 50% Xmax eve deal for myself. I was a bit concerned about the LED PCB, but it's big and thick (think 2.1mm) - sort of equivalent to an aluminum housing, but it has a ton of space in the cavity below. That would definitely benefit from a copper PCB replacement!!

pics or it didn’t happen :smiley:

It happened... At work now, but I did before/after ceiling bounce measurements and the difference was significant. Don't think I got pics of the actual mods though. Wasn't setup for beam shot pics -- just got wall beam shots setup yesterday, did the X9 mod bout 2 weeks ago, just before xmas.

Ohh, found the PM, here's a snippet:

"For the X9, decided to go with 3.74A (KD V2 3.04A + 2 7135 350ma). On a ceiling bounce got 154 lux, compared to 98 lux before the mods. This puts it above my HD2010 (w/U3 1C) and not so far off from my modded Crelant 7G9 at 162. A short test outdoors confirmed those numbers – better than the HD2010, close to th 7G9. The X9 appears to have less spill than the 7G9, so it’s distance should be well up there. I ran the tests with a Panasonic unprotected (short) cell. Still need to do the switch mod to shorten it, making more room for the battery. Also did a 6 minute test, standing the light by itself – it gets pretty warm – was hoping it would do better. If you have the light in your hand, the temp is tolerable but there is heat build-up near the top end of the battery compartment. Now if you held the light for the 6 minutes, the heat build-up would be less because your hand actually helps pulling away heat. I left the small spring on the driver because it offers some compression and protection of the driver, so need to reduce the tail cap end by 2-3 mm’s. I’ll let you know when it’s all done, just thought these test results were interesting — the light is doing real well with the 2 mods – emitter and driver, and has an excellent beam pattern. I used Arctic Ceramique on the star mount and used 22 gauge wires, heavier than originals."

Update: the more I think about it, a copper PCB in this light would be a killer. Run it at 4.5A, under the copper PCB, mount another circular hunk of copper pressed/epoxied/thermal greased into the frame of the host, and wow, perfect setup for a serious budget based thrower with a dedomed XM-L2 U2!! Maybe can compete with the 1StopThrowUp (1Stop De-Dome) shop...

Get those copper PCB's, please!! I will take a bunch!

I would like a couple of 32mm slugs for mtg2,

lets go overdrive!!!

Wooody

Exactly what I was thinking. :wink:
I have a de-domed X9 with a 8x7135 driver and to be honest I don’t think de-doming works as well in the X9 reflector as it does in others. A XM-L2 U2 driven at 5 amps or so wont go amiss though. I am defiantly going to make the same thing (but de-domed) with an STL-V2/ SN6X-2 if this goes ahead! (150-170K lux anyone?). 8)

The SN6X-2 / STL-V2 uses the same board, 6th photo here: Review: Maxtoch SN6X-2 [ XM-L 2x18650 Thrower ] OEM Flashlight

I got the Small Sun ZY-T619 coming for $13 cost from the 50% WallBuys deal. Hoping it's internally the same as the X9, but that's ashame de-domed the X9 didn't work well there. Was hoping to get a super budget single cell thrower...

Hmmm, just checked my X9 and its seems to be only operating at 2 amps (again). I thought I fixed that. Regardless: to give you an idea of throw a de-domed X9 with XML T6 at 2 amps very nearly matches a Shadow JM26 XML U2 at 3 amps. I have U3s (and replacement drivers) on the way so will try those.

Anyway: back on topic I have had no response from the above MCPCB producer. Maybe they are busy, maybe they are all on holiday… I don’t know but I will try a couple of Asian producers and see what I can find.

In the mean time: is there anyone here good with PCB design software skills? I have a basic understanding of it (DesignSpark) but not enough… if I had something I could present other then some rough dimensions and requirements that would help I am sure. So if anyone wants to have a play around I would really appreciate it.

PilotPTK would be your man :slight_smile:

+1, he is amazing. He designed both of my 20mm multi-XML boards.

Hmmm, 32mm XM-L U3 for my X9, that kinda sounds nice :smiley:

I would like some 16mm for sure and probably a few 32's also.

If they are 16mm ill be in for more :slight_smile:

I have made a rough sketch of what I need drawn up on CAD or better yet in a PCB design program: Is there anyone here with CAD skills? It should be fairly easy to scale the design and change the die footprint to adjust it to a 16mm and XPG/E/C board.

Its missing quite a few measurements but it gives an idea of what I am after.

EDIT: One more thing: any dimensions / placement of things you think should be changed on the above? (I know the solder mask needs to be removed from between the anode and cathode of the LED pads)

Gerber - CAD Files

Enjoy.

PPtk

With that much space, it’s kind of a shame to only put one emitter… I prefer this - they’re wired in parallel, so if you don’t want to populate more than one, no big deal… More flexible….

PPtk

Gerbers - CAD Data

reminds me of this, very pricey but intriguing nonetheless

http://www.led-tech.de/en/High-Power-LEDs-Cree/CREE-Solutions/7-x-CREE-XM-L-U2-on-copper-round-PCB-LT-1847_120_117.html

Huge thanks PilotPTK!!!

Just heading out the door so wont be able to do anything with these until tomorrow but will make some more inquiries then. Thanks!!!

Just realized I forgot screw holes: guessing these are best left to be drilled where they want by the end user?

Sorry about the double post but just got a reply from Altus:

XLampXML2_1 Customer P/N: XLampXML2_1

Description: 2-Layers MC PCB (Without impedance control/ Without blind & buried
vias),Aluminum Substrate , 1 oz starting copper, HASL,THK: 0.059”,Green
Mask, White Silk, Unit Size 0.63” diameter, No others special requirement ( X
out allowed)
Special Notes:
Tooling: $250.00 E test: Included

  1. Quantity Price Lead 20
    time 15days
    Extended
    Price
    Note $378.00

So, not sure if I’m reading it right but they somehow read “copper” as Aluminium and it looks like price for those is around $20 each (when doing 20). Really have to go (late for work)…………

Part of the reason (I suspect) that they quoted you so high is that they quoted “2 Layer” boards. These are only 1 Layer.

To get an accurate quote, ask for the following.
Copper Core MCPCB. 0.8MM overall thickness. Single Layer. 2 Oz Copper. White mask. Black Silk. 1.26” Diameter. No Vias.