the finished product
If you’re a construction enthusiast in any way, this custom headband flashlight holder is the product for you. Fabricated from a sturdy acrylic mount and hand-stitched 3/4” elastic headband, this holder secures a small flashlight to the user’s forehead so that tasks can be completed more easily in dark environments.
Product Features
- Simple, elegant design
- Allows user to hold flashlight while still using both hands to work
- Stretchable headband allows for “one size fits all” design
- Sturdy clip attaches to existing flashlight
Click here to download the promotional flyer for this product. | |
File Size: | 622 kb |
File Type: |
How was it made?
First, a series of sketches were drawn in order to quickly generate ideas. These design ideas are shown in the slide show here.
Once a design was chosen, a CAD model and a 2D drawing were made. This 2D drawing was first printed on paper to verify dimensions. The dimensions were slightly adjusted, and then the final 2D drawing was laser cut into 1/8" thick acrylic sheet.
The bending of the acrylic part concluded the construction of the flashlight mount. Then, the headband was created using the materials shown in the image below. A 3/4" acrylic band was cut to approximate length (I used my own head as a guideline) and sewn together by hand using high-strength thread and a needle.
The image below shows the general process of stitching the horizontal part of the headband.
The image to the left shows the stitching done to attach the back-to-front headband strap. This secondary strap was looped around the horizontal strap and stitched together, and the thread was used to attach the elastic band to the plastic mount at the front of the strap. The image below shows the finished product, with the flashlight removed.
|