Specifically large aluminum ones like this:
Is it CNCd?
Lathed?
Molded?
I might try to find a place that can make something similar or make it myself if possible, rather than spend $700+ on an entire light just for the body.
Thanks! :)
most are machined, most are CNC
save your money and find a host and build what you want.
I looked and couldn’t find any hosts that looked anything like this.
I have access to almost any tool necessary, I just need to know the right one to use for the job.
If it’s too complicated I might just save up and buy a whole light…
Im not sure about right english name, multi-axis machine center?
It looks like lathe, have big stepper as main motor, smaller second reverse spindle and tons of cutting/drilling/milling/threading tools in big turret head.
Host on photo is defenetly machined (not molded). Solid proper sized piece of aluminium is cheap enought.
Thanks 
I think it’s bot molded (or extruded) and then machined.
So you make a coarse mold and then machine it.
Otherwise you have a lot of wasted material.
Al piece Ф100*200mm weights about 4kg - less than $20.
A lathe can be cnc…. The biggest part of the body (with the letters) can be done on a lathe. The cilindric form that go’s unto the body can be done by a milling machine but if you change the design a bit u could produce it on a lathe. The handle (if it’s one piece) I think is molded. No way they are gonna carve that out of a solid piece of what ever material they used. Probably the whole thing is molded and then machine the things that can’t be molded if they produce a lot of them. It’s much more cheaper that way then machining every piece.
Thanks guys Makes sense.
I’ll talk to some people and confirm the machines they have are capable of machining this.
Like this?
They’re called 5 axis CNC mills.
Don’t think one was used for the light in question. Regular lathe for main body, mill for frame; would be my guess. There are some die cast flashlights by Nitecore (and copies by TanLu) but I guess you already know that.
I think he meant a lathe with a live tool revolver.
Basically a lathe with a mill inside.
Something like this: http://d2n4wb9orp1vta.cloudfront.net/resources/images//cdn/cms/PM0412_NewMachineFor_c.jpg
As mentioned above, I’d say multi-axis CNC (combined turning and milling with various tools). This is also the reason that a lot of manufacturers don’t make their own lights; these machines are really expensive, and no doubt that such a factory has several of those to increase productivity.
I don’t think 6061 is molded first, and then machined to save a couple of bucks on scrap. These alloys indeed cost a couple of bucks per kg, but the machined material is often sold back to the supplier (depending on variables; I assume you need to be a reasonable big player). With machining you can start with a 10 kg block for example, to end with a 100 gram piece. Obviously you pay for 10 kg first, but you get quite of that investment back selling the remains.
It is also less likely to mold the aluminium first, as you would lose heat treatment. “6061” is merely the chemical composition of the alloy; the alloy itself is not so strong. A heat treatment is given, almost always T6 to gain strength. This “T6” denomination is often not even mentioned. Flashlight manufacturers often don’t even mention what alloy they’re using; it’s “aerospace grade”.
If you want to mold and machine lights (or large parts in general), this means you first have to custom mold the parts, then heat treat all these molded parts to gain strength, and finally perform machining. This is way more expensive I think than to machine only, especially the heat treating is a costly process.
There is another alloy often used for flashlights, which is 6063. This alloy is used often for extrusion. Meaning, the original material prior to machining is created using extrusion.
6061-T6 is bought as a circular bar with an outer diameter, whereas 6063-T6 is bought as a tube with an outer and inner diameter; meaning less time machining. A flashlight with an integrated shelf requires a solid circular bar, whereas a light with a screw in/press fit pill can be made from 6063-T6. The design choice of the light therefore has influence on the available material. I do not know about the difference in bulk price between these two materials.
There are no doubt some other alloys used as well, although I hardly read about that. The only other alloy that I know of is 7075-T6, which is much stronger than the 6000 series alloys, but price is higher and more difficult to anodise. An example is my beloved Thrunite V3.
And then there are some exceptions like some Nitecore EC models which are die cast.
No, no and one more time no.
Most mass market parts are machined with one material set only.
You have aluminium rod (required diameter, 3 or 6 or 12m length), you put it in big collet and all machining should be made in this set.
If you will use regular lathe, then regular boring machine, then regular mill with tons of extra equipment, you will spend 10 more time on setting and zero basement and etc.
There are tons of such videos on youtube:
P.S. +1 to hIKARInoob. You can save few $ on material, but other mechanical properties of molding alloy does not allows to use same machining rates (speeds) and this can only cause problems with tools and longer machining time.
Same could be said about mold, parts that are made this way should be 99% ready after it. There is no sense in combining lots of different processes unless you are using gold.
Who are you talking to? Edit: Nevermind, I’ve read your edit. Cheers.
Exactly what I mean, those machines can make everything!
Satisfying to watch it. 
Groupbuy! Let’s do it!
Definitely need a group buy—The set up time for one would be a killer—-just as well make at least 10-20
Cnc machined like you can see here
Haha I didn’t know people would actually be interested in paying for an aluminum can with fins xD
Looks like the hardest part would be making the threads on the inside of the cylinder, which would 100% require a cnc lathe rather than manual.
If I do try to make one and it turns out good I’ll definitely make some more and let you guys know
Does anyone know what aluminum regular flashlights are made out of like the ones from nitecore, fenix, etc…?
6061 or 7075?
Most of them just say aircraft grade aluminum, and wikipedia says that that usually refers to 7075, but 6061 and others are also considered aircraft grade.
I’ll probably make it out of 6061/6063 either way, since 7075 is like $500 for a cylinder large enough for this type of light.
Makes me realize why these lights cost thousands of dollars…
Wow that’s awesome to look at, specially as a Nitecore fanboy.