Flashlight Mod using GB Laser Diode

[chimo]

Here are some pics of a mod I have started using Senkat's GB diodes and an old 3xAAA flashlight converted to take an 18650.

Proto driver board (will be shrunk to fit in flashlight head).  LDO Linear regulator (~80-250mA):


Module:


Head:


Parts (anodizing removed on all parts but the head):


*****PART 2*****
Blank PCB


PCB Ready for etching


PCB with some components mounted


Driver with trimmer pot mounted on underside


Driver in head


Laser Module


Assembly shots


All together now


With one Li-ion and the LDO, all I could get out of it was 185mA.  This configuration should also work with 2x CR123A or 2x RCR123A Li-ions.

Paul

 

[AJ_Dual]

The flashlight host looks like the "Element" sold by Sam's Club, is it?
Did it have a driverboard, or was it direct-drive of the original LED?

 

[chimo]

The flashlight host looks like the "Element" sold by Sam's Club, is it?
Did it have a driverboard, or was it direct-drive of the original LED?

It came from a store called "Princess Auto" - lots of Chinese stuff. This light was sold under the "Power Fist" label. It had an incandescent and 3 LEDs. The switch was 2-way - no driver board.

 

[chimo]

Part 2 stuff added to first post.

Paul

 

[LarryQ]

Nice job!!...

Very well done...

How small is that driver board?

Diameter??

How much are you putting to the Diode??
Voltage, Current....

More details please!!!!

I LOVE THAT DRIVER BOARD!!!!!!

Super job!!!


LarryQ

 

[chimo]

Thanks Larry,

The driver board is larger than it needs to be (probably around 17-18 mm dia). I just used the inside of the tube to trace a ring and then kept inside it. The components are fairly spread out as well. The drop out of the IC (~1V) is a little too much to really crank out the current with a single Li-ion. The lower and upper design currents should be 94mA and 379mA but it will not hit the higher current with a single Li-ion due to the large drop-out. With a single Li-ion it will deliver about 180mA to the LD.

Paul

 

[Things]

be careful with Li-Ion's, they like to explode if overcharged ;D ;D ;D ;D

 

[Things]

and they do it pretty violently too! ;D ;D ;D

 

[Things]

oh great work BTW!!!!

 

[Comidt]

and they do it pretty violently too! ;D ;D ;D

They most certainly do.
i had a lithium Polymer (LiPo) batt for RC Heli, touched the pos and neg together by mistake, tsssss....., through it outside, BOOM!, well not really boom, but you get the idea, SCARY. I got SUCH a fright.
Now I am EXTRA careful with those batts

 

[Comidt]

Oh, yeah, good work!!
How did you make the CB?
i heard you can print it out on a laser jet on paper, and soak it into the board to get a pro one, but not sure how to do it.

 

[SenKat]

There are many different ways to create your own circuit boards - I believe all of them require the use of acid to burn away the exposed copper ! You can use Phot-sensitve boards, and lay a printed transparency across the board, or draw it direct on the board with a sharpie, print it out on iron-on tansfer paper, and iron it on there yourself, etc....it can be a VERY fun and rewarding experience, a little costly to get involved in at first - and for some odd reason, when you move places, moving companies do NOT like to move a 5 gallon drum of acid in their moving van !

G !

 

[Daedal]

VERY nice work The PCB looks good, the solder work is flawless, and the end result is amazing!

This is very nicely done and very great result in the end indeed. I like the creativity you put into that.

Thank you for sharing;
DDL

 

[chimo]

This board was simple and the components are fairly large from an SMD perspective, so I just used a sharpie and hand-drew it. I have some of the Easy Toner Transfer paper, but that would have taken much longer to do. With the sponge-etching method, you only need a very small amount of acid so that's good as well!

There are many different ways to create your own circuit boards - I believe all of them require the use of acid to burn away the exposed copper !  You can use Phot-sensitve boards, and lay a printed transparency across the board, or draw it direct on the board with a sharpie, print it out on iron-on tansfer paper, and iron it on there yourself, etc....it can be a VERY fun and rewarding experience, a little costly to get involved in at first - and for some odd reason, when you move places, moving companies do NOT like to move a 5 gallon drum of acid in their moving van !

G !

 

[chimo]

Thanks!

VERY nice work  The PCB looks good, the solder work is flawless, and the end result is amazing!

This is very nicely done and very great result in the end indeed. I like the creativity you put into that.

Thank you for sharing;
DDL

 

[Comidt]

How do you drill the holes?