Drilling a Sunwayman V10R Ti's heatsink to accept tritium vials, as many flashlight enthusiasts wish to do, can be a difficult and/or expensive process which only gets worse the more holes are desired.
By 3D printing the heatsink, increasing the number of tritium holes actually reduces it's overall cost and printing it in brass also increases it's heatsinking abilities.
I therefore present my Finned Heatsink with 20 holes for 2x6mm tritium vials (not included) and designed to replace the stock heatsink on Sunwayman; V10R, V10R Ti and V10R ti+ flashlight models.
Although the current model has 20 holes for tritium vials, the number can very easily be modified to suit requirements as tritium vials are quite expensive.
Unfortunately due to resolution limitations in 3D printing, the two threads (1mm pitch) cannot be printed and need to be machined. O-ring channel re-working, re-drilling of the tritium holes to clean them out and open them up, re-facing the top and bottom surfaces to ensure that they are flat and smooth as well as a good outer surface polish is required to make the heatsink ready for installation.
The three possible material options are brass, bronze and silver.
However the Bronze material (90% copper, 10% tin) has quite a pore thermal transfer rate and should be avoided for use as a heatsink material.
The brass material (80% copper, 15% zinc, 5% tin) will be a marked improvement over the stock titanium heatsink but not the aluminium version.
The sterling silver material (92.5% silver, 7.5% copper) is one of the best metals for thermal transfer (pure silver being the best) and would make an excellent heatsink and a true performance upgrade from the aluminium stock part.
However, apart from silver, it would probably be easier to make a brass heatsink from scratch, than to do the required machining to the printed version, especially considering a lathe would be needed in either case.
Also drilling the tritium holes becomes a great deal easier if they can be drilled before the heatsink fins are cut and working in brass is generally much easier than working with titanium.
I suppose in conclusion these printed heatsinks aren't a particularly good idea but at least it's been proven to be possible.
There are some more photos of this object and other examples of my work, both 3D printed and otherwise, on my 'Tofty' facebook page