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What makes a Good Flashlight?

Good Threads
Believe it or not this has been a very good indication to flashlight quality, at least in my experience. A manufacturer that cares a lot for his products invests in this part of the design/manufacturing process too, even if it is a bit more expensive machining wise. He also invests in cutting tools proper replacement etc etc....Go for a cheap Chinese brand and you may cut your finger on them.

Good Electronics
While this is a knowledge not reachable by the average user an internet search can lead you to some good findings. Electronics Qualitydoes not only mean reliability and performance, but also less energy losses that translates into heat emitted - generally not good for the LEDs and the circuits themselves- but also wastes battery stored energy.
American electronics have an efficiency of about 90%, good Chinese electronics 75-90% and the el cheapo ones can go even as low as 50%!

Good LEDs
The speed the LED technology evolves makes for more than increased performance. A LED manufacturer that knows that his produces will change every year will transfer more R&D costs to fewer units made. That will raise the price of newer products, while the older ones get depreciated. That is a bargain for a flashlight maker than wants to keep cost down and/or profit up. There are several makers out there that make Good Flashlights but choose to use older LED generations. Go figure.
I suggest the user choose a newer generation LED light –or better stated, newer LED DIE technology. It is a bit like computers....Invest in the beginning more, and you will have to upgrade less frequently in the future.

Good O-rings
That makes for good waterproofness of your flashlight. Both when flashlight & water are static to each other but especially when there is movement involved. Thin – just for being there- O-rings do not guarantee a good seal. You got to feel the O-ring/metal part friction when screwing 2 flashlights part together.

Good Internal Structure
The way the internal parts mate plays an important role in flashlight performance. The body itself is used to transfer the electricity and current flows through touching metal surfaces and springs. Better (firmer contact) make for less electrical resistance and the subsequent losses. If we talk flashlights that output more than 600 lumens this is the number one killer of your light output and battery life. (I have measured up to 45% losses in output in some builds of mine)

What makes a Better Flashlight

Better Glass
It can be just Glass or it can be Pyrex Glass, Lexan polymer (offering shaterproofness), AR coated (Anti-Reflective) offering less light losses or UCL (Ultra Clear Lens) offering increased transmittance in the expense of rigidity.

Better Finish
Modern day Aluminum flashlights are either finished in grade II anodizing or grade III, also known as Hard Anodizing. The latter is the most scratch resistant, but in reality the thickness of the anodizing plays a role too....I have seem flimsy thin HA ano in cheap lights that scratches worse than a Surefire grade II ano....

Better Design
While most times it is cosmetic, there are 2 things that should be checked...Does the design help with heat emission in the LED/electronics area? And does it help with a secure grip, or even a more combat oriented one if wished for (like a grip ring, see the Rogers/Surefire flashlight grip)?

User Interface
The moment electronics were introduced into flashlights a world of new possibilities was made. Now you can choose various brightness’s and light effect modes (beacon, strobe, SOS). These are achieved by On-Off sequential use of one or two switches. Possibilities are endless including sequence programming and PC connection.
User Interface (UI) describes these flashlight on-off sequences to achieve the proper flashlight function. It can be intuitive, easy or VERY complicated. There is a light and a UI for everyone, so just spend 5 minutes more on studying if it fits you and your intended flashlight use.

Upgradeability
With the speed LEDs involves the question of what will happen to your old flashlight pops out! Can it be upgraded or better yet does it worth upgrading it? Some time it is too expensive to hire someone to mess with it (see Maglites) than buying a new light.
Take a look at the much awaited Surefire LX1, LX2’s small brother. Production has been pushed back to end of 2012. By that time the designed will have to be redone to use the LED technology of the era...Then it will be further delayed....So some designs are not flexible....these they will expire within 1-2 years of issue.
Some designs are modular like the Surefire 6P style flashlights with user replaceable components. These can be gifted with an extension of service life.

Service/Guarantee Work
This may seem self-explanatory, but it is more complicated than it seems. There are manufacturers out there that offer a no-questions asked replacement guarantee, but do not kid yourselves this has been included in the purchase price.
The harder question to answer is the manufacturer will be there in 2-3 years from now....With the way the flashlight scene evolves the answer can be NO in half the cases...

Price
Ho-ho! Thisisabigone! What else is included in the retail price? Guarantee work, sale promotion expenses, corporate expenses profit & financing, R&D work, new model development costs just for being modern/up-to-date? The answers are manufacturer specific....

that is all folks, at least for now