Abstract: A lighting device with thermal management may be, for example, a headlamp device that includes a light source and a housing. The housing includes a first portion comprising a first set of external surfaces adapted to operate as a first heat sink to dissipate heat from within the first portion. The light source is disposed within the first portion. The housing also includes a second portion comprising a second set of external surfaces adapted to operate as a second heat sink to dissipate heat from within the second portion. Substantially all external surfaces of the of housing are adapted to be exposed to ambient air when the headlamp device is in use and are included in the first and second sets of external surfaces. Methods and other lighting devices are also provided.

Abstract: A metal core circuit board assembly includes a circuit board having a through hole in an embodiment. A shaft for a pin is inserted in the through hole such that cap of the pin abuts a foil layer on the circuit board. The shaft diameter is sufficiently smaller than the through hole diameter such that the shaft is electrically isolated from a metal core for the circuit board. The cap is undercut about the through hole to further isolate the pin from the non-electrically isolated portion of the metal core circuit board.

Abstract: A metal core circuit board assembly includes a circuit board having a through hole in an embodiment. A shaft for a pin is inserted in the through hole such that cap of the pin abuts a foil layer on the circuit board. The shaft diameter is sufficiently smaller than the through hole diameter such that the shaft is electrically isolated from a metal core for the circuit board. The cap is undercut about the through hole to further isolate the pin from the non-electrically isolated portion of the metal core circuit board.

Abstract: A lighting device with thermal management may be, for example, a headlamp device that includes a light source and a housing. The housing includes a first portion comprising a first set of external surfaces adapted to operate as a first heat sink to dissipate heat from within the first portion. The light source is disposed within the first portion. The housing also includes a second portion comprising a second set of external surfaces adapted to operate as a second heat sink to dissipate heat from within the second portion. Substantially all external surfaces of the of housing are adapted to be exposed to ambient air when the headlamp device is in use and are included in the first and second sets of external surfaces. Methods and other lighting devices are also provided.