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Special Purpose Infrared (IR) Floodlight

Challenge

A unique need for a ruggedized and high-intensity IR floodlight for SOF nighttime operations led to the development of this product.

Solution

A special purpose IR floodlight used in harsh, dynamic, and varying unpredictable conditions. This sealed light includes an anodized, nitrogen-filled enclosure with thermal fins, high and low IR intensity settings, custom circuit cards and thermal protection to reduce power if the unit is accidentally left on during hot daylight hours.

Outcome

Battelle performed design for manufacturing efforts and collaboratively worked with suppliers to develop a cost-effective solution. An originally fully machined body/housing was converted to a custom extrusion that minimized machining time and cost, offering a net savings to the product of more than $145 per component and enabling a cost-effective solution for the market. Battelle has produced, and continues to produce, these lights with more than 1,000 made to date.