The initial concept used a modified housing Coast G32 Penlight with space to allow for a clothes pin style clamp. The thought was that a penlight was one of the most common items on a tech and if they needed to hold the light in place and use 2 hands for an inspection the feature would be built in.
After getting the buy in, we proceeded to create a prototype we could field test, survey and take to Snap-on to share with the product manager. The feedback we got from the product manager was that this needed to be more of a handheld size, not pocket sized. It needed more light, run time and better ability to position itself. It also needed magnets.
The factory's designers overseas had designed a light housing for a different proposal we wanted to pitch to Snap-on. We had taken this as a jumping off point and created two 3D models based on the main housing shape with a ball joint.
We printed both versions and preferred the functionality of the 2nd version. We just needed to test the magnet, spring, and clamp size / shape.
Using an existing circuit board, LED and battery I created the housing we would use to test the samples with.
Various clamp size / shape / spring strength / magnet location we tested
Prototype light clamped to a plastic shroud around an aluminum radiator grill during a personal VOC on a coworker's Ford Ranger
Prototype clamped to a hose deep inside the engine bay of a Ford Ranger.
While updating the Snap-on product manager we included an estimate on how we were planning on making the current design with an exploded view.
The product manager was underwhelmed by the adjustability of the sample, so we revised it based on a feature we had used on a different product. Since we didn't have enough time to make the sample correctly, we glued the shelled upper half of a previous sample to a solid sample of the lower half to get validation in the field the next day.
Testing the grabbing and working ability of the updated base.
Evolution of the product samples with the clothes pin style clamp with samples that we prepared to be sent out to shops for feedback.
During our follow up meeting with Snap-on, the designers stepped in to revise the design to ensure it didn't exceed the profile of the main housing when viewed from above. Right sample is what Snap-on came back with. We took to redesigning the light with silicone jaws to better clamp objects, allow the jaws to open wider, 2 stronger magnets to better grab ferrous surfaces, better finger holds to improve ergonomics when opening with oily or greasy hands, while following the Snap-on design language. Working with the factory we also made the arm more robust that included reinforced arms to withstand the drop testing.
Our redesign of what the factory came back with (pink pen pointing to the design we proceeded with). You can see this 3D print in the previous image.
The factory and our team recommended to the Snap-on design team to add some kind of texturing to aid in grip issues the techs could encounter when using with oily, greasy or wet fingers. This was a general texture presented to start the conversation.
The Snap-on team refused the texture or ridges to aid in finger grip. After submitting the drawings with updated 3D the factory came back with this rendering.
Testing the T1 sample on my own vehicle and through drop testing we found a couple improvements for aesthetics and durability.
Communication with the factory about how to revise the mold after seeing breakage occur in this area of the part. The factory wanted to add more ribs, but we were able to revise the design by simplifying how the loads were distributed.
During drop testing we found that the plastic pivot for the clamp was failing much sooner than we would like due to the thickness of the material. We revised the material to a glass filled nylon and added fillets as we could to resolve the issue.
We had also requested the clamps durometer be increased since this allowed slipping or like in the picture rolling on a surface.
These are the changes completed after the final tooling sample
The final product sold through Snap-on. Coming in at 450 (near constant) lumens for 3 hours and drop test rated for at least 10 drops at 1m and 10 drops at 2m (in reality we had recorded 10x1m and 80x2m in our tests).
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Snap-on Clip Light
Listening to VOC feedback from techs there was a growing need for a light that wasn't completely reliant on the magnet for composite or non ferrous surfaces. We took this idea to Snap-on and got their buy in with a request to increase the size, light output and how it is positioned. During the process we also worked alongside the designers at Snap-on to make this product the best we could. Many hours of personal and field VOC were conducted, as well as testing for required light curves and drop testing to ensure it lives up to the Snap-on brand.
