Lamp Finishing

In our existing wide range of standard lamps, First Light is already manufacturing all of the termination styles used within the Laser and IPL industries.

We also have the ability to custom design connector styles for specific lamp designs. Despite the wide range of connectors available, they can be broadly categorised into four main types:

Base Connector

This is probably the most common method of finishing lamps. The connector is machined in Brass and then Nickel plated. It is possible to use Stainless Steel but this has a higher skin resistance than Nickel/Brass and is only ever used for continuous lamps where the operating current is relatively low.

Customers can specify any diameter and length to suit their specific requirements.

It is also possible to offset the connector from the glass dome of the lamp as shown in the photograph. This is done occasionally when extremely high energy pulses could cause cracking of the lamp seal.

Lamps with base connectors can be fully submerged in the cooling water or the o-ring seal can be positioned on the lamp envelope.

Plastic Sleeve with Base Connector

An alternative to a simple base connector is the addition of a plastic sleeve. The sleeve is used to mount the lamp o-ring allowing the whole lamp to be fully submerged in the cooling water. First Light uses a black engineering plastic with excellent dielectric strength (30KV/mm) which can withstand temperatures up to 170oC.

It can be machined to any length and diameter that the customer requires.

This is fixed to the lamp using a special high temperature epoxy adhesive (250oC) and can be offset from the lamp dome to improve cooling.

The electrical connection is then made to the Base connector as usual.

Flying Lead

Many lamps use either an uninsulated or insulated wire as a termination. The insulation material should be specified to suit customers’ specific requirements in terms of dielectric strength, temperature requirement, flexibility, etc. Please see the table below for more information.

  UV Resistance Dielectric Strength (KV/mm) Upper Operating Temp. (oC) Flexibilty
Silicon Good 20 200 Excellent
PTFE Excellent 24 250 Poor
PVC Average 14 70 Good


Customers can specify any wire size for the termination in either AWG or mm2

The wire can be terminated with either a base connector or industry standard plug.

Plastic Sleeve with Flying Lead

An alternative to a simple flying lead is the addition of a plastic sleeve. The sleeve is used to mount the lamp o-ring allowing the whole lamp to be fully submerged in the cooling water.

First Light uses a black engineering plastic with excellent dielectric strength (30KV/mm) and can withstand temperatures up to 170oC.

It can be machined to any length and diameter that the customer requires.

This is fixed to the lamp using a special high temperature epoxy adhesive (250oC) and can be offset from the lamp dome to improve cooling.

The electrical connection is then made to the flexible wire.

Unfinished / Plain

An alternative method of terminating the lamp is to leave the lamp unfinished with a simple Tungsten wire. This can be Nickel plated, Solder dipped or Gold plated.

Typical wire diameters are 1mm, 1.5mm, 2mm, 2.5mm or 3mm.

If your required method of finishing not covered by the above examples please contact the First Light technical team with your requirement.

Lamp Mounting

It is important to remember two key points when designing the electrical connections and mounting of lamps.

1) The electrical connection should have a large area of contact to the lamp termination. Dirty or oxidised connections or small contact area can result in high resistance and heating or arcing at the point of contact.

2) The lamps should be mounted in such a way to allow expansion of the lamp and flexibility. If the lamp is mounted rigidly the lamp can be stressed which can lead to cracks or breakages.

Mounting using o-rings or sprung connectors is recommended.