What exactly is potting as it pertains to flashlights? What do you use, and where exactly do you put it in the module? Any links to instructions, pics or videos would be appreciated.
Potting is encapsulating the driver and wires soldered to it in either epoxy or a heat sink compound like Fujik( basically caulk). This can prevent the wires from breaking at the solder joint. Some methods of potting can aid in the transfer of heat from the driver to the pill. Care must be used in that some potting compounds that are either conductive or capacitive can adversely affect certain drivers.
8) :p
I thought potting referred to faraday cages.
there is also a method of putting it in a tube, and running butane through it…
or in another use of the phrase… it is good for heavy use like use as a firearm light. like said, fujik, or another non conductive compound would be best.
In guitar pickups, it’s dipping the pickups (with or without covers) in wax until the bubbling stops, indicating all the air has been replaced with paraffin. If pickups are not potted, they tend to be microphonic and can squeal and feedback like there’s no tomorrow. Some of the older “vintage” Fender single coils weren’t potted. Some value this sound; I don’t. They sound awful to me.
Humbuckers in nickel covers pretty much have to be potted, or they squeal and scream like a coyote caught in a snap trap.
Probably nothing to do with potting in lights, but I was in a nonsequitor kind of mood. 
Worked for a pickup company and we potted the pickup bobbins in hot wax under vaccum and then the entirw assembly in a custom 2 part epoxy
Here's the Wikipedia article for general reference:
http://en.wikipedia.org/wiki/Potting_(electronics)
And a thread where a member tore down a fully potted Malkoff module:
Potting is a good way to make sure all of your electronics stay in place and sometimes can act as a heat transferring agent. On some of the custom flashlights that I have built I potted the driver using a 2 part 5 minute epoxy or the two ton epoxy. They both work very well. The two ton epoxy will stay pliable for a longer period of time and therefore is a bit more manageable. It is good to do in case you ever drop your custom flashlight, which I have done many times. It will assure that the wires will never come loose. Also, the epoxies I described wont expand when hardening so you wont have to worry about components coming loose. Good luck.
Now thats funny.
A little advice if you use Fujik for potting give it plenty of room to expand when it dries or the driver will get pushed right off breaking the solder joints.
… and comes out the holes like marshmallow fluff through a garlic press.