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Originally Posted by greentick
Add Princeton Tec to your list. Most (if not all) of their headlamps are made in the USA, if that matters to you.
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- Princeton Tec (19 models, made in USA)
- Petzl (14 models, made in France)
- Black Diamond (12 models)
Those are the Big 3 makers & many models are under $50. The Surefire Minimus (4 models) & Maximus (2 models) are high end tactical lights. And there are lots of other good headlamps available so there's something for any job you have.
Warranties vary by maker & model, anywhere from 1-year to lifetime. Some will withstand immersion in water (look for O-ring or gasketed sealing surfaces) others are water resistant.
Most headlamps run LEDs that provide longer runtimes than those using incan bulbs. The biggest complaint about LEDs, whether in headlamps, hand held flashlights or weapon lights is that color rendering is poor.
Something really important is the UI (User Interface). Headlamps that do a dozen different tricks often use a UI that's either confusing or challenging to learn. The Petzl website shows videos of each model & explains the UI - they looked complex to me but may suit you just fine.
Power source is another key point - some run AA, others AAA, a few use CR123 (as used in Surefire lights). Weight varies widely among different brands & models. Most use an elastic head strap but some can be detached from the strap & adapted to helmet or MOLLE mount. It's impossible to recommend a particular brand or model without knowing the 'must have' features & your operational needs.
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... I use mine all day long I go through a lot of batteries so I would suggest a rechargeable one or you can purchase rechargeable batteries ...
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Some makers offer rechargeable versions using their own proprietary battery pack. Before purchasing one check on the cost of a replacement pack since it may be really high.
Many (but not all) headlamps accept AA & AAA rechargeable cells. Most cells are rated for at least 500 charges & some claim double or triple that number. Buying a charger is a one-time investment costing roughly $25-$50 and some chargers handle a huge range of cells (AA, AAA, AAAA, 18650, 17500, 16340 (RCR123), 14500, etc.) After buying the charger the cells are cheap to buy & offer a very low cost per hour of runtime.
The chart below is from Sanyo, maker of Eneloop brand rechargeable AA & AAA cells. At this time the Eneloops have the highest capacity & longest life in these sizes. Battery technology is constantly evolving & something else may well replace these.