Part 1- Flashlight Disassembly Study
Before any other reseach or designing began. I had a a Rayovac flashlight that I did a documented dissasembly on. In dissasembling the flashlight, it helped me gain a better understanding of how the product worked and the parts that were neccesary to build a fuctioning flashlight. Along with understanding the working mechanics of the flashlight. I performed some basic material and construction research, to find out what materials the flashlight was made of and the processes used to manufacture it.
The flashlight is made up of about 15 parts.
1. The Case
2. Contacts (Qty 2)
3. Springs (Qty 2)
4. Switch
5. Reflector
6. Lamp
7. Lens
8. D Cell Batteries (Qty 2)
9. Lamp Retaining Collar
10. Head Cap
11. Head Trim Ring
12. Conductive Ring
Part 2 - Modified Client Persona
Client persona is the "Outdoor Tradesperson". They work as a skilled laborer or in a trade based job and enjoy spending their free time outdoors. They need a flashlight a flashlight that will trasfer from on the job to recreational use.
Part 3- Research
In my design and research, I focused on dual usability. I wanted to create a flashlight that our persona is able to use in all aspects of their life, meeting their needs for work and recreational use that is primarily outdoors.
I conducted research through online and in store product research, examining the wide breadth of flashlights and features that are currently on the market. I purchased some of these and used on my own to perform various tasks. These flashlights included a Maglite, a medium duty flashlight, a headlamp, and a tactical flashlight.
In addition, I conducted interview research with three different people whose lifestyles matched that of our persona. From the interviews and some supplemental research I walked away with a list of needs. The first need was for it to be “rugged” and “durable” and constructed out of a lightweight material such as aluminum or polymer and to be drop resistant and waterproof or at least weather proof.
The second need was for a high light output with an adjustable beam and a long battery life. Universal battery compatibility was also a necessity.
The last need was to have at least one way for the flashlight to be hands free and for it to be lightweight and small enough to easily keep on their person at any time.
Part 4 - Concept Sketching
Inital concept sketching ideas
Part 5 - Initial Concepts - First Five Concept Drawings Created for Persona
Inital concept sketching- All flashlight were designed around using the AA batteries. The body of the flashlight are all designed to be waterproof or weatherproof and LED powered.
The flashlight has a battery indicator so the user never finds themselves in the dark with a dead battery. It is also a small thin flashlight for it to be easily stored in the pocket.
This flashlight was given an articulating 360 degree head to try and help solve the problem of the beam of light not being in the correct position to illuminate in tight corners. The light emitted also changes colors for day or night vision.
Small form factor with an easy to grip textured sides and a wrist strap for a form of hands free carry.
Small round body with rubberized inserts and a hooked carrying strap for hands free carry.
Part 6 - Revised Concepts - Present to Client at Inital Meeting
Refined the articulating head and added a removal spring loaded clip.
Reworked the pen light idea to have a pocket clip on the side of the flashlight an a removable mouthgrip on the back of the flashlight. Several sources in my research prefered holding their flashlight in their mouth but found it to be uncomfortable. I attempted to solve this problem by giving the flashlight a contoured mouth grip on the end made of the same material as mouth guards.
Part 7- Final Concept Sketches
From the client meeting and presentation the mouthgrip flashlight was the most prefered choice. I modified the flashlight to give it a rubberized impact and roll resistant head cap. The battery indicator stayed because that became a need for the client after seeing the idea but has been made more streamline with the body using LEDS and it only illuminates at a tap of the power button to wake the indicator.
The client did not think he would personally use the mouthgrip but knew many people who woulutd use the feature. So it was kept as an option but I added another opton of a small removable storage compartment on the end of the flashlight that can be used instead. The clip was also removed and a optional thread insert was added to the body to allow the user to purchase and add on additonal mounting accessories. ie clips, hooks, straps
Part 8 - Sketch Model
Foam sketch model to test shape, size, contours, and usablility to the hand.
