A high-performance, flashlight project. This design prioritizes cheap high power flashlight creation with a single-layer PCB layout, making it cost effective.
This project is engineered for [e.g., high brightness/long battery life]. By using a single-layer design, we simplify the manufacturing process while maintaining robust electrical paths.
- PCB Layers: 1 Layer (Single-sided)
- Material: [Recomended Aluminum (or copper $$$) PCB for heat dissipation]
- LED Count: [10]
- LED Type: [CREE JU7070 K Series (I used JU7070BWT-K-B40ED0000-N0000001)]
- Drive Current: [0-1200 mA depending on the voltage (700 mA at 11.8 volts)]
- Input Voltage: [10.5-12.4 Volts (optimal is 11.8 V to not release the smoke)]
- Power: [With 10 LEDs 0-148.8 W (82.6 W at 11.8 V)]
The board is designed with large solder pours to handle the current requirements of high-power LEDs and to reduce voltage drop across the circuit.
- Substrate: Aluminum-core PCB is highly recommended if running the LEDs at maximum brightness to prevent things from getting too toasty.
- Solder Mask: [I chose white (it's the cheapest option on JLC for aluminum)]
| Component | Type | Quantity | Notes |
|---|---|---|---|
| LED | [JU7070BWT-K-B40ED0000-N0000001] | [10] | [Color Temp, e.g., 5000K] |
| Resistor | [Not used] | [0] | Current limiting |
| Switch | [Insert Type] | 1 | [e.g., Reverse clicky] |
| Battery | [DCB 120] | 1 | [Had cheap Dewalt batteries laying around] |
| [NOTE ON BATTERY: MAKE SURE THAT YOU CEHCK YOUR INPUT IS AROUND 12V (11.8 V is what you should aim for the higher you go, the more heat you make)] |
- Fabrication: Export the Gerber files located in
/fabricationand send them to your preferred PCB manufacturer. - Solder Components: * Apply solder paste or flux to the pads.
- Place the LEDs, ensuring correct polarity (Anode vs. Cathode).
- Use a reflow plate (recommended for Aluminum PCBs) or a soldering iron.
- Housing: Fit the PCB into the [Insert Housing/Enclosure Name]. Ensure the LEDs align with the optics/reflector.
- Testing: Power the device using a limited current source first to ensure there are no shorts.
/hardware- KiCad design files./fabrication- Ready-to-order Gerber files./enclosure- 3D printable files (.STL) for the flashlight body./docs- Datasheets for LEDs and components.
This project is licensed under the MIT License.
If you know best practices for thermal vias and stuff like that. Feel free to contact me, I want to learn how to do them.