Can I be explained how potting works? I understand that the electronics on the driver are flooded with epoxy to give the driver structural toughness and the elements resistance? Is that the case? Would any epoxy work if one wants to DIY? Is there a significant difference that potting makes? Would doing that affect heat dissipation?
Potting also gives much better heat dissipation then air. Good potting into the pill protects from shock like dropping and weapon recoil. Adds to waterproofing.
I personally would not attempt this yourself. My opinion.
wikipedia on potting
here is a thermal adhesive silicone intended for electronics
posted in use here
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I actually chose their 704-BL version, claims to be more liquid.
btw, I bought this potting compound randomly, it’s about 0.6USD in China, didn’t know it’s so expensive overseas.
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thanks for sharing info
I found Kafuter 704 on Aliex
“K-704B Electronic sealing insulation glue strong high temperature resistant waterproof airtight adhesive”
They wanna say it’s an electrical insulator.
And in fact, almost any substance has better thermal conductivity than air. Also drivers can generate a limited amount of heat and can withstand high temperatures better than LEDs.
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thank you, not electrically conductive makes sense 
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As far as I know, I haven’t seen anyone have done a similar test, it’s not rocket science, but indeed no one has done this.
I guess it could be that modern well made drivers are enough shock resistant that potting only gets some marginal effect, no many people or manufacturers care.
Epoxy resin potting usually requires two components to be stirred and mixed, which will produce bubbles during the process. It may be necessary to remove the bubbles with additional process such as vibration, heating, vacuum etc, not so easy for diy.
Soft silicone potting is not as difficult, but provides only limited impact resistance. If your light is already well waterproofed, uses MCPCB, and has no exposed electronic components, then soft silicone potting is not necessary.
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Technically true, I think, but may ignore convection.
For instance a down-filled jacket may be a better thermal insulator than the same jacket without down, just inflated. In both cases it’s the air that isolates, but down keeps it from circulating and thus transfering heat better than conduction alone.
I don’t know how that translates to potting, but I would imagine some local insulation because of it. Is that consequential? Maybe not…
One of the uses of those silicone potting compounds is thermal conductivity, so it won’t. As well as the space inside such electronics tends to be narrow and there is little convection.
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All you guys are talking about heat transfer meanwhile the main advantage of potting is resistance to vibration. This is why potting is used primarily on light to be used on weapons. These same light are not lumen monsters. Most of them are 2000 lumens at most. Take for example Modlite.
From Modlite web site:
Modlite systems fully pot their light heads for impact, vibration, and shock protection, making them heat resistant, waterproof, and shock resistant. This potting process ensures the lights can withstand harsh environments and rigorous use, such as the recoil of a SCAR 17. Modlite also fully pots the drivers in their lights, according to their website.
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Yeah, it was just temporarily derailed for a bit. Actually, I don’t even really like that these potting compounds conduct heat, the LED give off more heat and it may heat up the components on the driver through these compounds, this may have unintended effects or advance temperature control step-down on high power lights.