Nemo High-Powered Dive Light

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One of my projects at Gizmo Engineering Ltd. was to develop a waterproof housing for a high-powered LED array containing ten 100W LEDs. The housing was to be marketed as a high-powered dive light for commercial and rescue applications with partner company Nemo Power Tools.

Iteration 2

Housing a 1000W array of LEDs in a waterproof shell required that the housing be strong enough to withstand water pressure at depths of up to 100 meters, but also thin enough that heat could be wicked away from the array fast enough to prevent overheating. To improve heat dissipation, management decided to submerge the electrical components in a coolant, requiring that the housing be waterproof from the inside and out.

The first iteration of the housing featured a large internal compartments to house the batteries, which connected to a compartment that contained the LED Array. The compartments were contained and made waterproof via an extensive path of o-rings and screws around each compartment. Initially a rubber insert inside the hand grips provided a comfortable grip; however these grips were postulated to complicate assembly of the top and bottom components of the housing and were later scrapped.

The second iteration saw the addition of a simpler rubber attachment to the hand grips. Such simplification of the hand grips provided much more space internally for the o-rings and for other additional components: a screw-cap charging port on the back of the housing for easier use, as well as a light intensity slider on the front the device for simple control.

Iteration 1

Iteration 2

After my internship, Nemo Power Tools used my model to develop advertisements for the dive light as an R&D product. The second iteration of the product can be seen at https://nemopowertools.com/product/nemo-high-powered-dive-light/