The New Design project is called Personal Light Source “TORCH“. It can be used as a common flash light at many places, where personalized light is required for various purposes and used in day to day life. It is made up of very basic components like a Bulb of 2.6 watt, power cells of 1.5 watt, a connecting wire and the body. The body has other essential parts, to hold the basic components like, the transparent surface at the top for the protection of the bulb, light reflector, bulb holder, wire connection and switch control.

The body is made of polypropylene plastic material from a sheet of A4 size, facilitating the shape of reflector cone, power cells housing, wire connection, switch control, self standing position and ergonomic grip.

A flashlight is a portable, battery-operated device used for illumination. A typical unit consists of one or more dry cell batteries, arranged in a line, inside a battery compartment that forms the handle of the light. The flow of electricity, from the batteries to the bulb at the front end of the light, is controlled through a switch mechanism placed between the batteries and the lamp.
The modern battery powered flashlight was created in 1898 by Joshua Lionel Cowen, the original owner of the American Eveready Battery company. Cowen originally developed an idea for a lighting fixture composed of a metal tube with a light bulb and a dry cell battery. Eveready salesperson, Conrad Hubert, turned the metal tube, light bulb, and the battery into the world’s first flashlight, and started selling the batteries and the flashlight. (Source: Google)
In the last hundred years, advances in technology have resulted in flashlights with hundreds of different styles and features. Flashlights are now made with rechargeable batteries for multiple times and special operations, such as working underwater or in high-temperature conditions.
From the history, till today, the flash light or torch has been used in different places, under different circumstances to facilitate various operations. The essential and basic components are packed in a plastic and metal molded body. Even then, its simple function was never further explored in a new way, till today.

From the point of view of value engineering, the analysis and the audit of components, the manufacturing process, assembling the parts, operation in use, aesthetics and color have further inspired to make it more basic in terms of its production and usage. The objective is to make the flash light, user friendly in an A4 size sheet with flexible materials, having all the functions and fun.

I am an Industrial Designer and a Professor, in India, for the last 31 years. I make self initiated designs and innovations, take client projects as consultancy and impart knowledge in product design. As a part of my profession and academic responsibility, I always think of the problems and projects, from simple products to technically complex products, for myself and for the students.

This has provided me with an opportunity to think of the scope of a new design, where there is no client or a sponsor. It has become a self initiated attempt to innovate and design. Often people get fascinated by coming up with such innovations for the first time, without any assistance, guidance or help; which gives them confidence and enjoyment.

From the user point of view, we do many things ourselves. The distinctive design makes it very practical. An example making a cigar and then smoking it is the ultimate joy for passionate cigar smokers. Self production exists at an industrial level, as well as at a personal level, for all applications.
As with so many products, what makes it so engaging is its combined simplicity and functionality whilst bringing in portability, at the same time, into a very compact space. On the other hand, this Personal Light Source “TORCH“can provide illumination for many activities, where you do not have the space or the desire to store.
Something very simple can have a great aesthetic appeal as well. It should be able to cater to varied needs of life with the required amount of illumination. It can be a handy emergency light, for more mundane functions while travelling. It also has a notable reputation as an excellent travel companion, could be a distinctive gift article and it can even be used in medical emergencies or varied army usages.

“Do it yourself” has a range from button to balloon. It is a challenging task to do something new, since the Personal Light Source “TORCH“have simple functions and components. The value engineering approach has been the route to the new design. Today, it is the rule of technology, and most things are expensive that still offer new materials and techniques, to explore new trends and designs.

There are many things one can do, when one has the desire to see the things done in their own way. You can think of many projects and products that can be done in a ‘do it yourself’ way. One requires the basic things and needs to have a plan. Things are best done by ourselves, basically, because the only apprehensions we have is about ourselves and it becomes marketable, when others are considered as ultimate consumers.

‘Do it yourself’ has an added advantage because it saves time and allows you to make modifications in the product because, in essence, one becomes the designer and the user of their own product. Sometimes while completing projects one ends up spending more time with themselves and usually, enjoys it. Many people like doing things in their own way because it gives them an opportunity to understand the things better.
The first version of ideation was with the use of the paper, by hands on experience, and not with the help of the computer. This has given the hope and vision to refine and improve the various details regarding the position of essential parts in the body design. Next, the appropriate polypropylene material was selected due to its flexibility and availability in the sheet form and because it is easy to work with. Second prototype was made manually to ensure production and functionality. The polypropylene sheet form facilitates ease of cutting, folding and bending etc.

After testing the functions, the laser cutting techniques were tried to enhance perfection, considering the mass production. It is possible to make it by injection molding process with required modification in detailing. For example the reflector can be a part of the cone itself, with metalized coating and electrical connection forming the integral part of the body made by copper printing. The majority of the shapes that are used in the device are geometrical such as circle, cone and cylinder. The thickness and cut edge profile helps to lock the surface easily and manually. There are possibilities of various sizes and volumes to be made.

The reflector is made from metalized polyester sheet material. It allows the same techniques to cut, fold and make it into a conical shape. It is easy to assemble in cone and aids fixing of the bulb. To protect the bulb, a PVC transparent flexible sheet is provided, which can be easily inserted in to the surface of the cone.

The properties of Polypropylene and other plastic materials have been exploited in the new design for bending, rigidity, flexibility, tensile strength, folding, creasing, live hinge, color, detailing in texture and shapes to simplify its production and usage.

The value, in terms of cost for production of this product, will be much cheaper than the existing flashlights and torches. But in real life it will be of immense personal value because of its simplicity and functionality. The simplicity of transforming it into a useful end product is very easy and it is possible to manufacture it with very basic hand tools like profile template, cutter and other materials. It does not require any formal education or training to re-produce.

This can encourage various people, from students to the skilled craftsmen, to make it themselves. Students may explore it from the learning science and design point of view and craftsman may explore from the earning point of view. It also has the possibilities of self employment at various segments of the society, such as the source of income generation for the physically challenged or for a single person entrepreneur.

The varied possibilities of marketing ranges from commercial product to a gift article to corporate gifts and so on. There lies the possibility of branding it and advertising the company logo and the slogan, on its flat surface by print media. It also has possibilities of personalized or customized information for various purposes. The information can be provided in print, texture, or by holes made using laser techniques.

Its sustainability as a material is an added advantage. It is durable; polypropylene has long life hinge property, and it is washable as well. It does not get damaged due to the flexibility of the body material.

Further, it has the possibility to incorporate LED (light emitting diode) light and other sizes and shapes of the batteries, for a wide range of color and applications for illumination requirements. It can be hung at any place in an appropriate situation with linear materials and is easily affordable.

It has one material plastic, one property of flexibility and can be made by one person, which has numerous possibilities for use by many.

This can encourage various people, from students to the skilled craftsmen, to make it themselves. Students may explore it from the learning science and design point of view and craftsman may explore from the earning point of view. It also has the possibilities of self employment at various segments of the society, such as the source of income generation for the physically challenged or for a single person entrepreneur.

The varied possibilities of marketing ranges from commercial product to a gift article to corporate gifts and so on. There lies the possibility of branding it and advertising the company logo and the slogan, on its flat surface by print media. It also has possibilities of personalized or customized information for various purposes. The information can be provided in print, texture, or by holes made using laser techniques.

Its sustainability as a material is an added advantage. It is durable; polypropylene has long life hinge property, and it is washable as well. It does not get damaged due to the flexibility of the body material.

Further, it has the possibility to incorporate LED (light emitting diode) light and other sizes and shapes of the batteries, for a wide range of color and applications for illumination requirements. It can be hung at any place in an appropriate situation with linear materials and is easily affordable.

It has one material plastic, one property of flexibility and can be made by one person, which has numerous possibilities for use by many.