Check out “One Stop Throw Shop”, or wait and see what the new Fenix TK 61 can do when it comes out. There is a thread on CPF. But, one stop throw does asphericals that I’m sure are not the typical square.
Dereelight Xsearcher.
To be clear, it's not the recoil throwers that produce a square image. Recoil throwers, and aspherics, project an image of the LED die. If the die is square, the image is square. If the die is round, the image is round. The problem is that all of the current high output emitters have square (or squarish) dies. There are LEDs with round dies, but they're not what you'd call 'high output'. A slightly de-focused aspheric is probably the best you can do at this time.
In fact spill can be reduced in reflector flashlights. Tiablo has anti spill tube add on.
http://www.inovatech.co.uk/shop/Tiablo-A10-G-Anti-Spill-Tube.html
A Luminus sbt70 behind an aspheric might create the effect you are looking for. It might be a lot of work though!
Good idea but massively overpriced. It's a tube, come on. 
What do you get when those are a series of tubes?
A TN31mb (OSTS) might be close to what your looking for. It still has some spill - all non aspherical lights will - but its minimal. MUCH less than a K40, TN31, or other popular throwers. The light does a very impressive job of throwing a tight spot at a distance with minimal spill.
It’s not cheap, but it’s an excellent quality choice for a dedicated thrower.
Could you not cut the die like DBC did to his MTG2? You would still have the lines through the die, but it would be a circle if its possible.
Nah that only works on MTG2 (and similar designs - XB-D, XT-E) where the phosphor covers the entire substrate, XML/XPG only has phosphor over the square die itself. It's already as small as it can be.
Anyone know if an aspheric on top of a reflector would produce a rounded off beam?
It still gives a square beam (did it with a ZY-T13 and sold it to travish on LPF. Kept the reflector in and trimmed it to hold the lens in the perfect spot)
Reflector in just limits the spill, but it will always have a die projection with an aspheric lens
It would give square hotspot plus some side spill (reflection of reflector).
reflectors focus the light forward thus limiting spill. Take a reflector out of a light and try it; it will have a ton more spill than with a reflector
Tom,
This combination will produce the most interesting projection of light you ever seen,
Beam will be like clouds on the sky which are pulling you into square hole
Especially if used with OP reflector.
Here is the beam (any idea why BLF system does not allow me direct insert of this picture? I only have "leave the page" option when try to insert picture, and when I click it it does not post anything)
http://img24.imageshack.us/img24/7795/grobl2resize.jpg
There are light like Wolf eyes nitehunter (cloned by uniquefire UF T20 :) ) that have small reflector inside. It gives more spill but ugly ringy beam.
Do you want a beam profile like this ? (TN31 in smoke):
Yeah….something like that. Thanks,HB
Wow lumi - that is pretty freaky looking - think I saw that before, when I was abducted and taken to an alien planet (
).