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EDCO Mini v0.1

On this page: Against the best 60 mm keychain lights · Specifications · Light and runtime · Using the light · How it is built · Electronics · Cost · Drawings and animations · What has been checked · Open points before the first order · Files

EDCO Mini is the small sister of EDCO v0.2: a sealed keychain light of about 70 mm, made to beat the best 60 mm keychain lights on light, throw, battery and water. It comes in two sizes:

  EDCO Mini-16 EDCO Mini-14
Cell one 16340 (Vapcell INR16340 T6, 650 mAh) a made-to-order Ø14 × 35 mm high-rate LiPo cell (about 400 mAh)
Body / head Ø20 / Ø22 mm Ø17 / Ø19 mm
Length 73.5 mm with the keyring tab 69.4 mm
Versions Mini-16 (no magnet) and Mini-16M (two magnets in the end of the tail tab) Mini-14 and Mini-14M

Both run a Luminus SST-20 LED behind a TIR optic, with red and UV side lights, a keyring tab at the tail with an obround hole for a split ring or a lanyard, and a waterproof USB-C socket on the side of the head. The M versions add two magnets flush in the end of the tab; the plain versions have none. There is no laser and no radio.

EDCO Mini-16M, black anodised: crenellated bezel, two side-light windows, the stainless button, a split ring through the tail tab (render)

Render made from the design files.

Status: concept (v0.1). The housing of both sizes is modelled in CadQuery and checked for fits, walls and interference. The firmware has the side lights and a board header for each size, and the light output is simulated with the LuxLibre simulator. The circuit boards are not drawn yet, and nothing has been built or measured. Every light figure on this page is simulated or estimated.

The Mini-16 is the main design. No high-drain cell of the Mini-14’s size (Ø14 × at most 37 mm) is sold today: the Mini-14 needs a cell made to order (see open points).

Against the best 60 mm keychain lights

The benchmark is RovyVon’s small keychain lights of the current (G4) generation: the A4 Pro (titanium), A9 Pro (copper), A3 Pro (aluminium) and A8 (polycarbonate, with side lights). They share one light engine: an SST-20 behind a small optic and a sealed 330 mAh LiPo cell. Measured figures come from independent reviews; where none exist, the maker’s claims are used.

  60 mm benchmark EDCO Mini-16 EDCO Mini-14 Mini-16
Light at switch-on, out of the front 608 lm measured (A3 Pro), 650 lm claimed 944 lm 978 lm better
Light at 30 s 416 lm measured (A3 Pro), 381 lm (A9 Pro) 944 lm 978 lm better
Light at 10 min 119 lm measured (A3 Pro) about 230 lm about 195 lm better
Peak intensity / throw 3,241 cd, 114 m measured (A9 Pro) about 11,000 cd, 210 m (estimate) about 5,600 cd, 150 m (estimate) better
Battery 330 mAh, sealed 650 mAh (950 mAh with the Vapcell T9) about 400 mAh (made to order) better
Runtime at about 115 lm (medium) 1 h 44 min (measured, falling from 118 to 67 lm) 2 h 38 min (113 lm all the way) 1 h 37 min (117 lm) better
Runtime at about 20 lm (low) 6 h 22 min measured 13 h 15 min 8 h 8 min better
Runtime from the brightest mode 1 h 13 min (High, measured; about 100-120 lm after the first minutes) 1 h 7 min (about 230 lm after the first minutes) 51 min (about 195 lm) about the same time, twice the light
Moon 0.25-0.5 lm, 72 h claimed 1.4 lm, 47 h 1.4 lm, 29 h worse (see open points)
Charging USB-C, 45-58 min measured USB-C at 1 A, about 55-60 min (estimate) USB-C at 0.5 A, about 55-60 min (estimate) about the same
Water IPX6 claimed (IP65-IP66 on some pages) IPX8 target, not tested IPX8 target, not tested better (if the test passes)
Side lights A8 only: UV 365 nm, red, warm white; UV for 100 min (claimed) UV 365 nm and red; UV for about 2 h 10 min UV 365 nm and red; UV for about 1 h 20 min same colours, no white; longer UV
Magnet, keyring, lanyard clip-on magnetic tail piece, magnetic clip, keyring loop at the tail a flat tab at the tail with an obround hole for a split ring or a lanyard; M version: two magnets flush in the tab’s end the same magnets built in; no clip
Size 60.5 × 15.6 mm (63.8 mm with the tail magnet) 73.5 × 22 mm 69.4 × 19 mm worse
Weight 17.6 g (A8), 24 g (A4 Pro, titanium), about 40 g (A9 Pro, copper) about 54 g (estimate) about 33 g (estimate) worse

The Mini-16 is better on everything except size, weight and moon runtime. The size and weight are the price of twice the battery and a body that can hold about 230 lm for a long time. The moon runtime can be fixed in the firmware.

The Mini-14 wins on light, throw, low runtime and water, but its made-to-order cell is only a little larger than the benchmark’s. It runs about as long at medium and less long from its brightest mode.

Sources for the benchmark: 1lumen A3 Pro G4 (608 / 416 / 119 lm, 3,025 cd, runtimes, 58 min charge), the zeroair.org review of the A9 Pro, June 2023 (571 / 381 lm, 3,241 cd), Battery Junction A4 Pro G4 (650 lm, 2,500 cd, 330 mAh, 60 mm, 24 g, IPX6, high to 80 lm within a minute), the budgetlightforum.com thread on the titanium A4 Pro (63.8 mm with the magnet, Ø15.5).

Front: crenellated bezel and the TIR optic (render) Underneath: the waterproof USB-C socket in the head (render)
Front. Crenellated bezel, three fins, the TIR optic. Port. The waterproof USB-C socket sits in the head’s wall; the plug rests on the head.
The UV side light on (render) The red side light on (render)
UV side light. 365 nm, out of a clear rod in front of the button. Red side light. Out of the second rod; the button’s membrane glows as the indicator.
Tail: the keyring tab with its obround hole and a split ring (render) Tail of the M version: the tab with two magnets in its end (render)
Tail. The round tube bevels down to a flat tab; the split ring or a lanyard goes through its obround hole. M version. The same tab, with two magnets flush in its end: the light stands on steel.

Mini-16M and Mini-14 side by side (render)

EDCO-18 v0.2, Mini-16 and Mini-14 (render)

Specifications

Item EDCO Mini-16 EDCO Mini-14
Size Ø20 body, Ø22 head × 73.5 mm (with the keyring tab) Ø17 body, Ø19 head × 69.4 mm
Aluminium parts (body, bezel, head insert; from the CAD) 23.4 g (M: 23.1 g) 16.1 g (M: 16.0 g)
Whole light (estimate) about 54 g, of which the cell about 20 g about 33 g, of which the cell about 10 g
LED Luminus SST-20-W Gen 2, 6500 K, on a 16 mm copper DTP board the same on a 12 mm board
Optic LEDiL FA10887 TINA-RS for XP-E, Ø16.1 × 9.7 mm, 13° with an XP-E (fit over the SST-20 dome to be checked) Carclo 12079 10 mm IP66 spot, flange Ø12.5 mm, about 6 mm tall; 89 % and 23° with an XP-G
Turbo (simulated) 2,850 mA: about 1,110 lm at the LED and 944 lm out of the front with the LED at 85 °C; about 10 % more in the first seconds with a cool LED 2,850 mA: about 1,110 lm at the LED, 978 lm out of the front
Throw (estimate) about 11,000 cd, 210 m: 10 cd per LED lumen assumed, from Carclo’s 10 mm figure scaled by the larger aperture about 5,600 cd, 150 m: Carclo’s 5.0 cd/lm with an XP-G
Cell Vapcell INR16340 T6: 650 mAh typical (580 minimum), 6 A, Ø16.5 × 34.0 mm flat top (claimed). For longer runtimes: Vapcell T9, 950 mAh, 3 A (set BAT_MAX_MA to 2100: turbo then about 800 lm) made to order: high-rate LiPo, Ø14 × 35 mm, about 400 mAh and 4 A (estimate)
Driver the EDCO v0.1 / FlashKa v0.7 power stage: TI TPS62095 4 A buck in the LuxLibre current loop (TLV333, 20 mΩ sense), DW01A + SE8830A protection the same
USB-C waterproof vertical SHOU HAN TYPE-C 16PFS LTH7.45 (LCSC C3020055, IPX8 by its name), axial, in the side of the head; its own seal ring seals in the hole the same
Charging 1 A: TI BQ24050 (2 × 2 mm, LCSC C2859551) instead of the TP4057; about 55-60 min (estimate) 0.5 A, about 55-60 min (estimate)
Side lights UV: Nichia NVSU233B-U365 (365 nm, 3.5 × 3.5 mm), about 250 mA from the cell (roughly 0.35-0.4 W of UV at the LED; it falls as the cell runs down). Red: a 2.0 × 1.6 mm power LED, about 150 mA. Each shines through a clear rod: fused quartz for the UV, PMMA for the red the same
Button Ø6.5 mm stainless cap on a sealed, glowing membrane (halo indicator), Alps SKRKAEE020 Ø5.8 mm cap
Keyring, lanyard a flat tab at the tail, 10 mm thick, with an obround hole 3.2 × 10 mm through it. A split ring of at least about 14 mm across (checked in the CAD with a 16.8 mm ring of 0.8 mm wire) or a lanyard cord goes through it an 8.5 mm tab with a 3.0 × 8 mm hole; a ring of at least about 12 mm (checked with 12.8 mm)
Magnets (M version only) two supermagnete S-05-02-N52N, Ø5 × 2 mm, N52, about 680 g pull each on thick steel (rated), flush in the tab’s end face with opposite poles out two S-04-02-N, Ø4 × 2 mm, N45, about 420 g each
Water IPX8 is the target, not tested. Seals: the optic gasket, the face O-ring of the head insert, the button membrane, the USB-C socket’s seal ring, the two bonded light rods the same
Firmware LuxLibre, board edco-mini-16 board edco-mini-14

Light and runtime (simulated)

LuxLibre simulator runs with each size’s board header: 25 °C still air, a full cell, the default profile, and 10 mA for the electronics while the light is on. Lumens are out of the front, with the LED at 85 °C.

  EDCO Mini-16 EDCO Mini-14
Turbo 944 lm, full for 45 s (the turbo timer); 56 s with the timer off 978 lm, full for 33 s (the temperature regulator)
High (1.5 A) 578 lm for 150 s 599 lm for 93 s
Sustained (temperature regulator, THM_LIMIT 48 °C) about 230-240 lm after 5 min (a dip to about 180 lm at 2-3 min), body at most 47.1 °C about 195-215 lm (a dip to about 170 lm), body at most 46.8 °C
Turbo from a half-full cell, at 30 s 837 lm 840 lm
On a 35 °C day full turbo for 26 s, then about 90-170 lm, settling at about 140 lm; body at most 47.9 °C 14 s, then about 80-140 lm, settling at about 120 lm; 47.8 °C
Runtime from turbo to the ANSI end point 67 min 51 min
Medium (244 mA, 113-117 lm) 2 h 38 min 1 h 37 min
Low (40 mA, 18-19 lm) 13 h 15 min 8 h 8 min
Moon (3 mA, 1.4 lm) 47 h 29 h
UV side light (1 W from the cell, kept constant in the simulator) about 2 h 10 min about 1 h 20 min 
cd firmware
make sim BOARD=edco-mini-16
build/luxsim-edco-mini-16 --preset board "2C W8000000"                          # turbo, then until empty
build/luxsim-edco-mini-16 --preset board --set MEMORY=0 --set MODE_1=104 "1C W30000000"   # medium

Using the light

Modes layout (as EDCO):

Over USB (the LuxLibre console):

UV safety: 365 nm is invisible but not harmless. Do not look into the UV window, and do not shine it into anyone’s eyes.

How it is built

Half section of EDCO Mini-16 (render)

From the front to the tail:

  1. Bezel. Crenellated, with three cooling fins. It screws onto the band’s external thread (M20 × 0.5 on the Mini-16, M17 × 0.5 on the Mini-14, 2.3 mm of engagement) and is locked with thread-locker. Its lip presses the optic onto a silicone gasket, and its inner shoulder clamps the head insert, metal on metal, against the band’s front face.
  2. Head insert. The LED holder: a cup for the optic, the SST-20 on its copper board on a 1.2 mm floor, a face O-ring on its rear face and a key in a band notch. The key stops it turning while the bezel is tightened, so the LED wires never twist.
  3. Head section. The front of the body, as large as the bezel.
    • USB-C: the waterproof socket’s shell goes through an axial hole in the bottom of the head. Its seal ring seals in the 2 mm wall, and the plug’s overmould rests on the round head.
    • Top: two clear rods carry the UV and red light out of the top, side by side in front of the button.
    • Button: above the socket, so the board is backed by the socket when the button is pressed.
  4. Main board in a POM sled. The board lies across the bore.
    • Underneath: the socket, the MCU and the driver.
    • On top: the switch, the halo LED and the two side LEDs.
  5. Cell. Its + strip goes to the rear of the main board. The − strip runs forward along the bottom of the cell.
  6. Tail. Closed, with three grooves over the end of the cell, then a keyring tab.
    • Tab: behind the cell bay, the round tube bevels down at 55° on two sides to a flat tab, 10 mm thick on the Mini-16 (8.5 mm on the Mini-14) and as wide as the body. Its end corners are rounded (R3.5 / R3) and its end edges chamfered 1 mm, so it does not wear holes in a pocket.
    • Keyring hole: an obround hole, 3.2 × 10 mm (3.0 × 8 mm), goes through the tab’s flats, with 1.2 mm of metal to the cell bay and 2.8 mm to the end. A split ring or a lanyard cord goes through it. The tab is thick, so the ring has to be at least about 14 mm across (12 mm on the Mini-14) to turn through the hole.
    • M version: two magnets are bonded into pockets in the tab’s flat end face, side by side, with opposite poles out. The light stands on steel on its tail; the ring swings aside onto a flat. Both versions are the same length.

Exploded view of EDCO Mini-16 (render)

Assembly (once, for good)

  1. Bench-test the cartridge.
    • Weld the strips to the cell. Solder the cell and the LED wires to the main board.
    • Test the cartridge on the bench and flash the firmware over USB-C.
  2. Insert the cartridge. Slide it into the tube with the socket facing its hole. Press the socket’s seal ring into the hole from inside, and check from outside that the shell sits centred.
  3. Fit the button and the windows.
    • Bond the two light rods into their holes with a UV-resistant epoxy.
    • Fit the clear pin, the membrane, the cap and the button collar (press-fit with retaining compound).
  4. Fit the head. Fit the head insert with its face O-ring, the LED board on paste, the optic and its gasket. Screw on the bezel with medium-strength thread-locker.
  5. Finish the tail. In the M version, bond the two magnets into their pockets, opposite poles out. Thread the split ring or the lanyard through the tab’s hole.

Electronics: what changes from EDCO v0.1

EDCO v0.1 EDCO Mini
SST-20 Gen 2 on a 10 mm board, LEDiL LISA3-RS-PIN the same LED on a 16 mm (Mini-16) or 12 mm (Mini-14) board, LEDiL TINA-RS / Carclo 12079
TPS62095 driver, 2,850 mA, DW01A + SE8830A unchanged
TP4057 at 500 mA 1 A charger, TI BQ24050 in WSON-10 2 × 2 mm (LCSC C2859551; low stock); its CHG and PG pins go to the HAL’s two status inputs, and its enable pin to CHG_SET (to be confirmed when the board is drawn). A linear charger at 1 A makes about 1.3 W of heat in the first half of the charge
waterproof USB-C on a tail board, 4-wire flex the same kind of socket on the main board, in the side of the head; no tail board, no flex
RGB indicator under a light pipe RGB LED under the button’s membrane (halo)
(none) side lights: UV through a P-MOSFET on GPIO9 (on when low; the strap pin’s pull-up keeps it off at reset), red through an N-MOSFET on GPIO10
ESP32-C3FH4, RT9080, NTC unchanged

The firmware gains side lights for every board that sets LX_HAS_SIDE:

Cost (rough estimate)

There is no workbook yet. The Mini has the same parts count as EDCO v0.1 less the tail board and flex, plus two side LEDs, two rods and, in the M version, two magnets; its metal parts are smaller. Roughly 650-750 USD for one light, about 220-250 USD each for five, all fees, shipping and VAT included (estimate).

Drawings and animations

EDCO Mini-16M turning about its axis (render) EDCO Mini-16M coming apart into its parts and back (render)
Turning. Mini-16M: the side-light windows, the button, the USB-C socket and the tail tab with its split ring. Coming apart. Bezel, optic, LED board, head insert, button parts and light rods, main board, cell, body with magnets.
EDCO Mini-16 body drawing EDCO Mini-14 body drawing
Mini-16 body: PDF, DXF Mini-14 body: PDF, DXF

The M body is drawn. The plain body is the same without the two magnet pockets (item 9 on the sheet). The drawings are A3 sheets at 2:1, made from the same parameters as the STEP files by hardware/tools/edco_drawings.py. Each has the outline, a section, the end views and a feature table with tolerances, and every dimension on it is checked against the solid (check report). The animations are made by hardware/tools/edco_anim.py. All of them are renders and drawings of the design: nothing has been built yet.

What has been checked

All numbers are in cad/edco_mini_interface.json, written by tools/housing/edco_mini.py.

Open points before the first order

Files

Path What
cad/ for each version (EDCO_Mini-16_*, EDCO_Mini-16M_*, EDCO_Mini-14_*, EDCO_Mini-14M_*): the body and the assembly as STEP; the bezel and head insert once per size (plain thread diameters)
cad/edco_mini_interface.json sizes, walls, fits, masses, the thermal split and the interference check of both sizes
cad/EDCO_Mini-16_body_drawing.pdf, EDCO_Mini-14_body_drawing.pdf (and .dxf, .png) the body drawings (A3, 2:1; the M body, with the magnet pockets marked)
tools/housing/edco_mini.py the CadQuery model (sizes in SIZES, common dimensions in class P): python3 edco_mini.py ../../cad --size both
tools/housing/edco_mini_render.py the renders: xvfb-run -a python3 edco_mini_render.py ../../assets (uses the FlashKa v0.7 renderer)
../tools/edco_drawings.py, ../tools/edco_anim.py the drawings and the animations of all EDCO designs: python3 hardware/tools/edco_drawings.py, xvfb-run -a python3 hardware/tools/edco_anim.py (from the repository root)
../../firmware/boards/edco-mini-16/, edco-mini-14/ the firmware board headers, each with the thermal model for the simulator

Licences as for the rest of LuxLibre: hardware CERN-OHL-W-2.0, firmware and tools GPL-3.0-or-later, this page CC-BY-SA-4.0 (LICENSING.md).

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