FlexPro LED Flashlight Stick

A flexible LED flashlight handle developed from an industrial design sketch into a production-ready, manufacturable product.

Gallery

A collection of snapshots from CAD design, prototyping & Real product

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Starting Point

The project started with an industrial design sketch and a clear product vision, but without any mechanical definition or manufacturable geometry.

At this stage, the design existed only as a visual concept.
There was no internal structure, no defined wall thicknesses, no parting strategy, and no validation for real-world use or production.

The goal was to translate the original design intent into a mechanically sound, manufacturable product—without compromising the look and feel of the sketch.

My Contribution

I was responsible for converting the industrial design concept into a fully engineered, production-ready CAD model.

My work included:

  • Building the complete SolidWorks model from scratch based on the design sketch
  • Defining internal geometry, wall thicknesses, and draft angles
  • Designing part splits and interfaces suitable for prototyping and manufacturing
  • Preparing clean, supplier-ready STEP files
  • Iterating on geometry to balance flexibility, strength, and manufacturability

Throughout the process, the focus was on preserving the original design language while ensuring the product could be realistically manufactured and assembled.

Final Outcome

The final result was a fully manufacturable flashlight handle design, ready for prototyping and production handoff.

The delivered CAD accurately reflected the original industrial design intent while meeting real-world engineering and manufacturing requirements.
All geometry was structured, parametric, and suitable for supplier review and production tooling.

Proof & Status

✔ Designed for manufacturing
✔ Production-ready CAD delivered
✔ Product launched and commercially available

The final product is currently sold on the market and can be viewed here:
https://olsatools.com/products/flexpro-led-flashlight-stick

Stress Analysis Validation Study

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