Forge 500

$280.00

Taxes included. Shipping calculated at checkout.

Forge 500 is an advanced 500W high-output searchlight kit built around a twelve-emitter optical array, active dual-fan cooling, and an Arca-compatible tripod interface.

Peak output: 500W / 45,000 lumens
Beam distance: up to 2,500 meters
Beam intensity: approximately 1,600,000 candela
Mounting: Arca-compatible tripod interface
LED array: 12 × 3570 automotive emitters, 5700–6000K, Ra70
Thermal system: two 50 × 50 × 140 mm heatsinks and two 5010 high-speed fans
Controls: stepped output, direct 500W, direct 0W, and moonlight mode
Housing: PETG-GF5 main body with PBT Pro lens support

Battery options

Without Battery (default): The battery is not included. Forge 500 requires a Makita-style 18V LXT slide battery pack (5S lithium-ion, 18V nominal / approximately 20V fully charged). Because the light can operate at up to 500W, the battery must have sufficient high-current discharge capability. Low-current, incompatible, damaged, or heavily worn battery packs may trigger protection, reduce output, or fail to power the light. Confirm the connector fit, polarity, and battery condition before use.

With Battery: Includes one compatible battery pack suitable for the Forge 500 power interface.

Forge 500 ships as an advanced parts kit for experienced builders and is not a fully assembled sealed light.

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Forge 500 is a 500W high-output searchlight kit rated at 45000 lm, up to 2500m beam distance, and about 1,600,000 cd beam intensity. Its twelve-emitter optical array, dual-heatsink active cooling system, display, and Arca-compatible tripod interface are designed for experienced builders and long-range outdoor use.

Forge 500 ships as an advanced parts kit, not as a fully assembled sealed unit. The package contains printed body parts, optical components, cooling hardware, and electronic modules for builder assembly. The default Without Battery version requires a Makita-style 18V LXT slide battery (5S lithium-ion, 18V nominal / approximately 20V fully charged) with sufficient high-current discharge capability for 500W operation. The With Battery version includes one compatible battery pack. Checkout and order processing run through Shopify. Order updates, shipping notices, and customer support should use the contact details provided at checkout.

Parts kit

Ships as separated parts. Forge 500 is not a fully assembled light.

Kit layout Forge 500

What ships in the box Separated

Simple final assembly

Not a fully assembled light. Ships as separated PETG-GF5 printed parts, optical components, cooling hardware, and electronic modules.

Forge 500 main module x1
12-lens optical assembly x1
1.3-inch display module x1
PETG-GF5 printed shell set x1
Rear cap x1
Battery foam x1
Screw set x1
Core hardware modules set

Output 500W / 45000 lm

Throw Up to 2500m

Mounting Arca-compatible interface

Structure PETG-GF5 printed body

Assembly guide 1 Seat body parts 2 Fit glass 3 Close rear cap 4 Tighten screws

Is Forge 500 fully assembled?

No. Forge 500 ships as a parts kit for experienced builders.

Is a battery included?

The default Without Battery version does not include a battery. It requires a Makita-style 18V LXT slide battery (5S lithium-ion, 18V nominal / approximately 20V fully charged) with sufficient high-current discharge capability for 500W operation. The With Battery version includes one compatible battery pack.

What tools are required?

The full build may require a 3D printer, soldering equipment, drilling and tapping tools, and general electronics assembly tools.

Can it mount to a tripod?

Yes. Forge 500 includes an Arca-compatible mounting interface for use with compatible tripod heads.

How difficult is the assembly?

This is an advanced high-power build. It is intended for users with practical electronics, thermal assembly, and mechanical fitting experience.

How does it manage heat at 500W?

The thermal system uses two 50x50x140mm heatsinks and two 5010 high-speed fans. Cooling performance must be verified during assembly before sustained high-power operation.

How do the controls work?

Short-press the upper button to increase output and the lower button to decrease it. Long-press the upper button for direct 500W output and the lower button for direct 0W. From 0W, short-press the lower button to enter moonlight mode.

Who is this kit for?

Forge 500 is for experienced builders who understand high-current electronics, active cooling, mechanical assembly, and safe testing procedures.

System	Specification	Value	Build note
Light output	Peak mode	500W / 45000 lm	Direct-access control allows the light to jump immediately to the 500W mode.
Beam intensity	Peak intensity	About 1,600,000 cd	Designed for highly focused long-range illumination.
Beam distance	Maximum throw	Up to 2500m	Measured reach depends on atmospheric conditions and target reflectivity.
Tripod interface	Mounting	Arca-compatible	Fits compatible tripod heads for stable long-range use.
Main PCB	Power management	SC8815A DCDC controller	The four primary MOSFET positions must use the specified component models.
Inductor	Power stage	EPC1770 / 4.7uH	Dedicated high-current inductor for the DCDC power stage.
LED array	Emitter system	12x 3570 / 5700-6000K / Ra70	Automotive emitters on a thermally separated copper base board.
Thermal stack	Heat dissipation	2x 50x50x140mm heatsinks	Paired with two 5010 dual-ball-bearing high-speed fans.
Housing	3D-printed shell	PETG-GF5	The main body uses glass-fiber-reinforced PETG; the lens support uses PBT Pro.
Display	User interface	1.3-inch / 12-pin display	Works with the two-button output control system.
Front optics	Lens array	12-head lens	Optional AR-coated tempered protective glass can be fitted over the optical array.

Reference parts list

Forge 500 build materials.

Component names, specifications, and quantities only. Purchasing links are intentionally omitted.

Group	Part	Specification	Qty
Main board	DCDC controller	SC8815A	1
Main board	Power inductor	EPC1770 / 4.7uH	1
LED board	Automotive emitter	3570 / 5700-6000K / Ra70 / 55mil x4	12
LED board	Copper base board	Thermally separated copper PCB	1
Printing	Main body filament	PETG-GF5 / gray	1 roll
Printing	Lens support filament	PBT Pro / white	1 roll
Thermal	Heatsink	50x50x140mm	2
Thermal	Cooling fan	5010 dual-ball-bearing / 11500 RPM	2
Optics	Protective glass	143.8x119x1mm / AR-coated tempered glass	1
Optics	Lens array	12-head lens	1
Display	Screen module	1.3-inch / plug-in 12-pin	1
Harness	GH1.25 2P lead	100mm / single-end lead	1
Harness	Soft silicone wire	Red and black / 12AWG	As needed
Harness	Soft silicone wire	Red and black / 16AWG	As needed
Mounting	Heat-set insert	1/4 x 6 x 8 imperial	2
Fastener	Heat-set insert	M2.5x5x3.5	29
Controls	Button cap	Black / 275 type	2
Fastener	Stainless hex screw	M2.5x8	28
Fastener	Stainless hex screw	M2.5x4	3
Fastener	Stainless hex screw	M2.5x25	4
Fastener	Stainless washer	2.5x7x0.5	4
Fastener	Self-tapping flat-head screw	M2.6x20	4
Assembly	Thermal double-sided tape	25mm x 0.15mm	As needed
Assembly	Shock-absorbing foam	2mm thick / 20mm wide	As needed
Assembly	Foam double-sided tape	2mm thick / 10mm wide	As needed
Power	Battery contact	Makita-style copper contact	1
Display	FPC cable	10-pin / 1.0mm pitch / 10cm / same-side	1
Alignment	Bushing	2.1x5x8	6
Assembly	Electrical tape	General purpose	As needed
Assembly	Thermal grease	General purpose	As needed
Optional tools	Bench drill	795 motor / JT0 chuck	1
Optional tools	Parabolic drill bit	2.05mm / copper and aluminum	5
Optional tools	Hex-shank tap	M2.5	1

Performance proof

Peak output 500W / 45000 lm

A twelve-emitter optical system delivers extremely high output for large-area and long-range illumination.

Beam distance Up to 2500m

The multi-lens front assembly is designed for long-range search and outdoor observation.

Beam intensity ~1,600,000 cd

High peak intensity supports focused illumination across very long distances.

Tripod mounting Arca-compatible

The integrated mounting interface allows the light to be secured to a compatible tripod head.

Specification-backed claims

Performance messaging is tied to concrete hardware: twelve automotive-grade emitters, dual heatsinks, dual high-speed fans, a dedicated optical array, and a reinforced printed body.