Reflector design is a very complicated thing, way above my head anyways. I have tried to make some reflectors of my own just by free hand on the lathe, out of aluminum. Turned out to be a lot of spill with no defined hot spot.
Basically the larger the better and the deeper the better. But there are many more things that determine how well the reflector will throw light. The emitter throws light from all sides of the dome in all directions. So when its in a reflector, the throw is determined by how well all those different angles of light coming from the emitter are reflected and in what direction. Where looking for straight forward, the parabolic reflector has to be designed to have curves which reflect the light at the proper angle for the given angle leaving the emitter. The more light rays that are captured in the design and the focus ability of the reflector the better it should throw. A lot of the side spill that happens from small reflectors is from the emitter light that is passing by the reflector. With a small shallow reflector the light coming from the led at say 10 o’clock and 2 o’clock angle position is completely by passing the reflector, shooting straight out of the emitter and giving lots of spill. With the same diameter reflector but with a deeper design the light may only escape the reflector at a 11 o’clock and 1 o’clock angle position giving less spill and more throw.
I don’t know if I have explained this to where it can be understood, it’s a pretty complicated thing. That’s the reason they make CAD software to design reflectors. The software can mathematically figure out the complicated angles and focus them in each design.
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We all no the difference between a stock incandescent mag reflector and a rebel mag reflector, their the same diameter, but with a different shape and deep. This might help a little with visualizing the differences. The rebel reflector is designed for a led.
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I have a HS 802 that with a XRE R2 throws really well. It has a very deep reflector. I thought I try it with a XML for a super thrower. It had a terrible beam with a xml, not a thrower anymore. The reflector while deep is not designed to catch light at the greater angles the XML produces over the tighter angle of the XRE. Took the XML out and put the XRE back in.
The reflector design and what its designed for are very important factors. Wish you luck gamezawy, it maybe a little trial and error.