Home > Flashlight 101 > Potting
There's no better way to increase the durability and reliability of a flashlight than to pot it! Look at the photo above...the delicate electrical components are exposed on many flashlights, if they're not exposed, they are being held in place with solder and solder joints tend to flex and fail. With the right potting material, these components are locked into place with no chance of damage. PFlexPRO Flashlights and Drop Ins are all potted using Stycast 2850FT. This potting material is popular in the aerospace industry. Potting protects the electrical components from impact (dropping), vibration (riding in a car or mounted on a bike), shock (mounted to a gun) and anything else that could damage the driver. PFlexPRO P60 Drop Ins have contact leads extended through the potting material to lock the mode group. To lock the mode group, just connect the exposed mode contacts with the conductive paint (available on request) and the mode group or turbo step down can't be changed. If you decide later to change the mode group or step down time, just scrape or sand off the conductive paint.
The Stycast 2850FT is also very thermally conductive -it spreads the heat generated by the electrical components to eliminate hot spots and burn out, then creates a thermal path to the host. Many flashlight failures are due to the electrical components overheating and not the LED failing.
Before potting, all PFlexPRO lights have a thermal isolation pad installed between the emitter platform and the driver components. This Isolation pad protects the electrical driver components (max temperature of 60°C) from the high heat generated by the emitter (max temperature of 150°C).