Dome Reduction Surgery

I tried the slice method and ended up projecting artifacts. Then, tried dedoming and didn’t like what it did to the to the brightness and tint. Thought I’d take a shot at reshaping the dome. The stock dome is shaped to direct light forward which is great for an aspheric. By flattening the top and rounding the sides, the light gets focused to the sides. This should help a lot with reflector lights especially short ones. I’m also hoping it’ll add yellow to the purplish rosy tint of this XML2 U3 2A. I’ll post results later. :beer:

I used a razor blade to get the desired shape, then used 1000 grit sandpaper to smooth. On the right, more phosphor appears at wide angles and less at narrow angles.

UPDATE:
When I get my drivers, I’ll try different refectors and adjust the focus but here’s a rough comparison in grayscale.

Light distribution of mule aimed up:

Focus is only close as I’m holding a standard C8 reflector against the LEDs by hand. The modified spot is actually smaller than it appears. The large corona obscures it:

The LED is focused mostly at bottom of the reflector so it has a large corona. The top half has almost none focused on it which gives it a tight spot. I was shooting for more in the spot so on the next one, Ill take less off the top.

UPDATE:
Didn’t feel like waiting so I installed my crippled Qlite in an extra C12 pill and tried different reflectors. Nothing much changed. I ended up liking the OP best. It gives a beautifully seamless transition from center to spill.

Here’s the best untouched color picture I could get. Both have smooth reflectors:

UPDATE:
You can see how the phosphor image starts to divide where the curvature is slightly too sharp. It doesn’t create an artifact because it’s barely divided and only at a specific viewing angle (in the corona). With a cylinder shape, two distinct images of the phosphor would be seen at nearly all viewing angles.

Here’s a rough estimate of the light distribution from the center.

I don’t see a noticeable tint shift in the spot but corona and spill are a less blue. It’s performing about how I expected. Where the stock dome had a well defined spot and a somewhat defined corona, the modified dome has a small bright center blending into the corona which gradually spreads out into most of the spill like a starburst.

UPDATE:
I think I got it figured out. I shaved a little off the top of an old XML and undercut the base. As a mule, it now spreads about 160 degrees instead of 180. The corona is no longer projected from the bottom of the dome but instead from the top so it’s smaller and not yellow! I think it could be much smaller or even gone completely if I didn’t flatten the top. The spot is bigger because the yellow light that normally makes up the corona is projected higher in the reflector and contributing to it. On the next one, I’ll just make the undercut and leave the top and see if the corona disappears and the spot size changes.

Ignore the brightness differences, the old modded XML is running on less than 3 volts. Note the lack of yellow in the corona.

UPDATE:
It took me a while to get a nice uniform shape but here’s the spherical dome. I found that the bottom needs to be perfectly scratch free to refract the light cleanly upwards. I can’t see how close the wires are so I’m not going any further. Spot size is the same as stock and corona is thinner and doesn’t have that blocky shape. Tint seems a little warmer but my camera exaggerates it.

Interesting, can you post beamshots of before and after surgery?

Will you need to stock electric paddles to bring back a dying patient for this procedure if there are complications?

I’m still waiting for drivers and hate to use the crappy ones I have only to replace it later.

Nice work. You created the rounded shape with the blade and just used the sandpaper to smooth out the blade marks?

I’m very interested in seeing some beamshots before and after surgery. Preferably showing the difference when used with aspheric or reflector.

‘Tuning’ the dome shape. Looking forward to the results!

You might have to use 1500 or 2000 grit sandpaper to get a good surface. I have no idea about an led dome, but to polish scratches out of glass 1000 Grit normally makes it foggy.

Looking forward to see your results, you might have a new mod named after you.

interesting method. :slight_smile:

I’m guessing he’ll need to go MUCH higher than that for a true polish, when I did my MT-G2 polish method all 1500grit did was tear it up. I had to end up using 10k grit to get it back to shiny.

Yeah, I’d think well over 2000 grit as well. Interested to see where this leads.

lightme, when you get this mod perfected, are you planning on selling the modded emitters to those of us who are unsure about trying it ourselves? I have been thinking a modded emitter to throw more light toward the reflector may give us a better beam profile, but I’m not quite ready to risk permanent damage to any of my LEDs yet. What I was thinking was that an inverse cone might be the trick, like those 5mm epoxy LEDs they use to make Christmas lights.

UPDATE:
When I get my drivers, I’ll try different refectors and adjust the focus but here’s a rough comparison in grayscale.

Light distribution of mule aimed up:

Focus is only close as I’m holding a standard C8 reflector against the LEDs by hand. The modified spot is actually smaller than it appears. The large corona obscures it:

Did the tint shift? Doesn’t look like it…

Do you have a de-domed led to compare?

As for polishing the LED lens, google moth eye led. I’ll remove the scratches and polish to a certain degree but a shiny surface is not best.

No, just domed and short domed but the spot size should be close to the same as a de-dome. No yellow and a big corona.

I changed the images to grayscale to show the gradient more clearly. My camera sucks and the light screws with the colors and brightness varies from one image to the next. When I get another comparable (same driver, reflector, LED bin) light together, I’ll make a side by side comparison with better pictures of the tint shift.

I don’t know about mass reducing domes but I’m gonna try using the lathe next time. If that works out, I would do it as a favor.

Compound shapes especially with sharp edges or corners can throw multiple images which is fine when you’re not trying to focus a single point. To throw light with a reflector you can only have one point source from all angles for a clean image. Large changes to the curvature can divide the light and make rings and such.

Back in early 2002, all the luxeon leds were “low dome” like your surgically altered led.
The “lambertian hi dome” was introduced shortly after and has been the predominant design we have come to know for flashlight use.

And don’t forget the batwing which was supposed to redirect the light to the sides making it perfect for reflectors


That’s pretty cool. What LED is that?

Luxeon III side emitter or batwing (Discontinued)

I wonder how would a modern XP-G2 / XP-L would look with a batwing dome attached… Anyone have one and want to test it out?