Pocket Torch using High-brightness L.E.D.

The invention of the high-brightness L.E.D. has opened up a world of possibilities in the realm of compact lighting products. When we were approached by L.E.D. manufacturer Lednium for developing a handy pocket torch, we carried out a quick survey of existing pocket torch designs. Much to our dismay, we found that a sheer lack of design effort, in terms of styling as well as usability. Most of the existing designs still follow the conventional form of a torch i.e. a uniform cylindrical form with symmetrical surface treatment. Little or no thought seems to have been given to stability on flat surfaces. The models that have pen-like clips use this as an add-on element having little or no correlation with the visual language of the product.

We started the design process with the objective of giving a fresh perspective to pocket torch design, making it a style statement rather than just a utility device. Extensive form exploration resulted in a bank of sketches showing diverse form factors and interesting design elements.

Some of the promising designs were shortlisted and refined.

One of the designs was selected for development in consultation with the client. The concept was assigned dimensions and put through a round of extensive feature refinement for finalizing the aesthetic.

The finalized design was subjected to a preliminary engineering review to understand the manufacturability aspects.

After some dimensional refinement, a CAD model was generated and rendered to explore different color schemes and finishes. The product form was reviewed for aesthetic appeal. This trendy design has a circular cross-section which varies throughout its length to create interest. The long depressions on the cylindrical body and the truncated front end further add to the excitement of the design. The recessed neck and color-coordinated clip help in maintaining a slender profile.

The concept proceeded to the design engineering phase, where it was detailed out in terms of parts and their assembly.

A rapid prototype of the design was obtained through the FDM process. The prototype gave a realistic feel of the product and vindicated our efforts towards ergonomic design. The design was approved and taken up for mass-manufacturing.

Being a small product with very little technical complications, the pocket torch often fails to get the design effort it deserves. Completing the design process in a detailed and systematic manner made us realize that the simplest of products can be made delightful to see and use through proper design.

Shoubhik Dutta Roy