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Portable 100W led flashlight

A monster flashlight containing a 100W 8500Lm led with big heatsinks and batteries.
With morse function to tell the night goodbye.

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This is a very bright portable light with proper cooling and an enclosure built from an old atx psu.
Every high power led should run cool so ot os mounted on a huge heatsink and a 120mm fan blowing the air into the psu case where al the electronics are.
The original fan from the psu still runs in the same place and pulls the air out of the back.
Nothing get hot at all. Even after long use it gets only warm.

All leds need a constant current source, so i mounted a big 600W constant current boost converter in the case supplying 3,2A at >32V.
At the moment it runs on a 5000mAh 5S Zippy Li-Po.

The lens and reflector are bought in a kit and can be mouted almost directly onto the led. I needed to cut an aluminium plate to mount the led and the lens.
It is brighter than car headlights and you can hold it in your hand ;)

The morse function makes this project connected and lets you send quiet messages through the night.

See it in action here in comparison to other flashlights:

And the morse function:

The light can be seen from a very wide area and is great for morsing through the night.

  • 1 × 100w led
  • 1 × Constant current boost converter at least 10A input and 3,5A output
  • 1 × Big heatsink
  • 1 × Battery or power supply capable of supplying over 100w at lbetween 12v and 20v
  • 1 × Arduino For pwm and morsing
  • 1 × 12v buck converter for the fans
  • 1 × Some switches At least one for power. more optional for more functions.
  • 1 × Lens and reflector kit
  • 2 × Banana terminals
  • 1 × Thermal grease

  • Added a morse function

    Yannick (Gigawipf)08/02/2014 at 18:15 0 comments

    To do something useful with the arduino in this project i added a morse function to tell the night what you think about it ;)

    It will send any text that is received via serial and return to normal brightness afterwards:

    It is possible to put the light and a raspberry pi anywhere and send messages over the internet into the darkness.

  • Power Terminals and Poti finished

    Yannick (Gigawipf)07/13/2014 at 18:23 0 comments

    Got the potentiometer and some high quality banana terminals fixed to the case.

    A lipo can be connected safe and everything works at high power.

    Video will follow soon.

    Next step: Video and maybe a strobe mode and a pushbutton.

  • PWM working

    Yannick (Gigawipf)07/08/2014 at 16:24 1 comment

    Almost all components are now stuffed into the case. Still looks awful but works great. 

    Cooling and PWM control are working fine.

    Next steps: cleaner wiring, making use of the switch and screwing banana plugs for power in and replacing the old power socket with the volt/amp meter.

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Martin wrote 11/25/2015 at 11:59 point

I wondered about the arduino, because for dimming I would just use a pot and adjust the constant current. It is not that great to PWM the LED current itself. This gives flicker (depending on frequency) and reduces efficiency. The efficiency of LEDs goes down with higher current. Therefore the overall efficiency goes down if you use high current pulses with pauses in between for dimming. It's true, that it is often done this way, but just out of convenience. You have a real switch mode converter, so you can drive it with DC.

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Yannick (Gigawipf) wrote 11/26/2015 at 19:12 point

Yes. I would also want to use current based dimming instead of pwm.

The reason i threw the arduino is was that i wanted to make some measurements like temperature, current, voltage and drive a display but i never got the motivation for that.

To reduce the pwm problems i increased the frequency so it won't be as bad on videos. But it is not that easy to regulate the boost converter with the arduino.

The easiest way would be to wire the pot with some resistors directly to the converter. Sure. But i am happy for now.

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Chaz wrote 08/08/2014 at 18:04 point
Cool, I actually built one of these. a few years back. but battery powered.
Here's some pictures.(sorry they are from ebay)
http://www.ebay.com/itm/161381801587?ssPageName=STRK:MEUNSOLD:IT&_trksid=p3984.m1562.l2649

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Yannick (Gigawipf) wrote 08/08/2014 at 18:49 point
very interesting design.
I am not sure if you find a buyer with this case.
Even if i like the idea. It could need some restauration ;)
Anyways the commercial 100w portable lights are often sold at way higher prices.

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