The Life And Death Of A Fantastically Brilliant Flashlight

August 31, 2011 by Mike Szczys 21 Comments

[Holzleim’s] flashlight build is quite impressive. And the rise and fall of the hardware is quite a story. He designed it as a handheld light, relying on batteries to power a multitude of high-power LEDs inside.From the collection of four 5350 mAh lithium polymer cells he was able to achieve a peak power output that surpasses 500 Watts!

Projects that make use of these powerful LED modules have heat dissipation as a major design element. With this in mind, [Holzleim] used large bars of copper as a mounting surface for each group of modules. The size and thickness of these bars made it difficult to use traditional soldering techniques to affix the bodies of the modules so he ended up using a clothes iron to ramp up the temperature high enough to reflow the solder. Once mounted, most of the LEDs were paired with optics, including that Fresnel lens at the center, to help focus the light.

To keep the batteries topped off, [Holzleim] designed his own external charger which can run off of mains or from a car’s electrical system. Unfortunately he must not have included a way to monitor the battery temperature because one of the cells failed, causing a fire that burnt out the components inside the flashlight. Luckily his wife was home at the time and got the failing device outside where it didn’t cause more damage. We’ve linked to his posts regarding the charging system, the properly functioning light burning paper with its beam intensity, and his sad announcement about the fire after the break.

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Building Infra Red Light Sources With Regular Lights

February 2, 2011 by Caleb Kraft 23 Comments

[Oneironaut] sent us another IR hack. This time it is a writeup on the best ways to create IR light sources from regular lights. Since normal flashlight bulbs emit a broad enough spectrum to include visible light and IR light, this basically comes down to filtering. [Oneironaut] explores different light sources and different materials in depth, along with great pictures to show his results. This is a great resource if you’re needing to do some night vision for cheap.

Chainsaw/flashlight Overkill

August 8, 2010 by Caleb Kraft 45 Comments

[Robbtoberfest] has earned our admiration with this crazy chainsaw powered spot light. It looks horribly dangerous, extremely inefficient, and woefully under engineered. We absolutely love it.

This could be plucked from a video game or a movie and seems to be one UV bulb away from being the ultimate post apocalyptic zombie vampire Armageddon weapon. He has taken apart a chainsaw and attached it to a DC treadmill motor using a couple of bike sprockets and a chain. That DC motor then feeds a car headlight directly. As you can see in the video, when he cranks the gas, it shines pretty brightly. The unfinished nature of this is due to a deadline for a contest on instructables, so he plans on adding a protective cowl, some fancy paint work, and a voltage regulator down the road.

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Building A Glue Stick Flashlight

June 9, 2010 by Mike Szczys 29 Comments

Building an LED flashlight is simple, right? Take a battery, connect it to an LED by way of a resistor. Alright wise guy, now make one that steps up the voltage for multiple LEDs and don’t use a boost-converter IC to do so.

[fede.tft] shares a flashlight built inside of a used glue stick case. It’s the perfect size for one AA battery (we’re always on the lookout for good battery cases), and a shape that we’re familiar with as a flashlight. The problem is that he wants two white LEDs but with just one AA cell he’s never going to have more that 1.5V available. He licked that problem, getting to 7.2V by designing his own step-up converter using one transistor, an inductor, and three passive components. To get the inductor he needs, a stock part is disassembled and rewound to suit. Maybe you just end up with a flashlight when all is said and done, but then again, the Sistine Chapel is just some paintings on a ceiling.

Switchmode LED Flashlight Upgrade

June 1, 2010 by Caleb Kraft 11 Comments

When [Neelandan]’s cheap flashlight’s internal rechargeable battery died, he scrounged for a replacement. Ultimately, the brightness of the light suffered with his new battery, taken from an old cell phone since he had dropped the voltage a bit. Upon inspection he saw that he would have to swap the individual resistors for each lamp to get the desired brightness again. This wasn’t really acceptable as he would have to repeat the process if he used another re-purposed battery with different specs. Instead, he added a new circuit to supply constant brightness until the voltage drops below 2.7 volts. We love to see hardware resurrected, even if it is just a cheap LED flashlight.

That’s A Big Flashlight

March 26, 2010 by Mike Szczys 57 Comments

Going camping? You’ll need an extra backpack to carry this flashlight along the way. On the business end you’ll find 500 five millimeter super-bright white LEDs, on the opposite end there’s ten times the number of controls you’d expect on a flashlight. At full power, the LED array pulls down 50 Watts, making us question the battery life of the unit. Check out the walk-through after the break. The LEDs are mounted on proto-board, making for some extreme point-to-point soldering. During the control demonstration there’s a background noise like a jet powering up, what’s that all about?

While this terrific torch brings a grin to our faces, we wonder if it wouldn’t do better as a vehicle mounted illuminator. Or if a microcontroller was tossed into the mix some creative code could make this a pretty powerful yet non-lethal weapon.

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Raid The Dollar Store For An Illuminated Umbrella

November 12, 2009 by Mike Szczys 23 Comments

diy-illuminated-umbrella

Here’s a quick and easy illuminated umbrella that [Mikeasaurus] built. How’s this for economical? He found an umbrella that someone left on the bus, and used an LED flashlight and clear poncho from the dollar store for the rest of the parts.

The scavenged LED circuit board is the perfect diameter to fit inside the handle of his umbrella. He removed the middle LED and drilled a hole in the board for the shaft to pass through. Although not well detailed, we gather he managed to shoehorn two CR2032 3v batteries underneath the PCB to power the device. The poncho is wrapped around the shaft to diffuse the light. This is a clever solution as the flexible plastic still allows the telescoping shaft to collapse down to its most compact size.

[Mikasaurus’] umbrella doesn’t make noise or emulate the weather but it is a clever idea. The low difficulty level and availability of parts makes this a great project to do with the young ones who don’t get included in your more intricate hacks.