It’s not only bicycles that get stolen, but bicycle lights too. When arriving at your destination, to avoid theft usually meant lugging around two bulky lights in your pocket. The overall product design challenge was therefore to make a front and a rear bicycle light so small and compact that they could easily and conveniently be carried around in a pocket but without compromising standard safety features from a traditional bicycle light.
Primary Technical Challenge
To achieve rotational equilibrium around the handle bar tubular element in order for the front lamp to be able to remain positioned horizontally pointing forward without rotating around the handlebar and to get the patented Dura-Loc™ plastic molded snap-fit mechanism that keeps the two lamps interlocked when assembled into a single unit after use and which also functions as a snap-fit mechanism for mounting the two lights to the bicycle, to continue "snapping" repeatedly without losing its memory over time.
In order to prevent the material losing its memory overtime the design has been incorporated with a second snap fit mechanism that when activated latches the two snap fits under force after use. This allows the material to return to its original shape ready to exert the same clamping force over and over because the bending radius remains as specified every time.
By combining the clamping force from the snap fit with the friction between the surfaces of the two parts and ultimately positioning the heaviest mass as close to the center of gravity as possible, it has been possible to balance out the moments around the handle bar and achieve rotational equilibrium.
Other than the obvious challenges described above, then the absolute hardest part of the whole project was to convince the world around me that it could be done.