Time for another weekly update:
Drive Current:
Our original intention was to set the drive current to 1000mA. However we've started doing extensive testing in regards to whether that really increases brightness output, since higher drive currents increase the die temperatures which in return reduce brightness. So our goal was to find the ideal setting where brightness is being maximized. Here is the relation between die temperature and drive current over time.
We have also measured brightness output in relation to time, however we first want to verify the results with a couple other LEDs before I'll post them. However what we have observed is that when you run the LED in the V3 at 1000mA that the light is only brighter for the first 20-30seconds... after that the LED die heats up so much that the brightness output after that time is actually less than when you run the light at a lower current...
Our preliminary tests show that the IDEAL SETTING for the V3 to get maximum brightness is 800mA.... Since our goal is maximum brightness, once we have confirmed the results we'll change the maximum drive current to 800mA.
Packaging Boxes:
Our supplier for the boxes sent us another prototype for the boxes the V3 will come in, this time with a darker varnish. Here are some photos in comparison with the lighter colored box.
We will likely go with an even darker varnish.. maybe something dark grey like below - grey would nicely complement the dark carbon fiber - while brown kind of intruduces a new color), however a darker varnish would require switching to a different wood (elm) so that the grain can still be seen.
Circuit Boards
We should get the copper core circuit boards in this coming week. Than we purchased most of the electronic components
Injection Molds
The only headache we currently have is with the 3 injection molded parts. We have placed the purchase order 3 weeks ago and we should have received samples by this week. A follow up revealed that the guy we talked to is on vacation and nothing has been done during these 3 weeks - apparently a company internal communication problem. However the company is looking into it to see what can be done. Kyle thinks they'll try to move it to the front and we hope to get them in time... I'll keep you updated.
Carbon Fiber
Order was placed and they are working on the tubes.
LEDs
We placed the purchase order UX0 bins... normal lead time is 4-6 weeks for those, however our friends at Seoul Semicond. are looking into what they can do. Did I mention that their customer service beats every other company out there. I mean flashlight makers are a small fish for them, but the respect they give you and the way they treat you, how they try to make things happen is simply awesome. We'll defenitely send'em a GatLight over once they're built.
Machined parts
Purchase order was placed, the shop got the full package with the final drawings so they likely are in the process of programming machines and starting with production. They actually have an exhibition coming up and they are eager to have some V3s on display so we'll try to make that happen.
Timing Estimate:
When we provided the original 3month time estimate, that was a pretty conservative guess. Even though we have some delays with the injection molding we still think our original estimate is valid.. depending on the solution we can find with the injection mold place hopefully earlier - if there is nothing else coming up.
Questions:
Number of lights, I think we passed 100 lights about a week ago.. so it's probably quite a bit more now. Also we're building a couple more lights than ordered. However we'll try to make the prepay units a bit different...as a thank you.
Style of the screws - they will be the same (Hex/same thread everything) as the ones on the V2 - except the radius will be a tiny bit smaller and the finish will be alot better. Also the cuts and features will look absolutely perfect. When you look at a stock screw with a magnifying glass they are everything else than perfect. We'll see what Swiss screw machines can do - normally those are used for very high precision parts like watches..