Wouldn't the spring help with impact? Have you done any drop test on the light? Did you update runtime with NiMH yet? Is the tail slightly chamfered? What titanium grade did you use for the prototype? You said alloy in the comments so I'm guessing grade 5 since it's the most common grade. Why don't people use grade 2? It has better thermal dissipation than grade 5.
Hello, thanks for your questions.
Yes, springs do help with contact as they will absorbe the changes in height of the batteries if they are smashed because of a violent shock. But in this case, as the length of the inner tube can be adjusted to the length of the battery set, then there will be no problem.
Yes, we have done drop test, and there is no signs of damage or failure. Lens are retained with an o-ring that will prevent cracking on it even on the even of a strong shock, and the PCB is small in diameter and thick, impossible to break unless you use a hammer and a nail.
Regarding the NiMH test, yes, we did it but we didn't saved the record... kind of stupid on our side. We will repeat it.
The titanium prototypes were made as you said with grade 5, as long as it is already an overkill. Heat dissipation is not an issue on a 1 Watt flashlight designed the way this one is... specially using an XPL-HI driven at 350 mA. Grade 5 has higher availability, I mean, you can get almost in no time every shape, diameter, wall...
Javier