Custom Illuminated Accessory Interface

Concept
A custom translucent accessory designed to integrate with a commercially available concert lightstick base, extending its visual identity through a flame inspired form with integrated logo detailing.

Design Challenge
The component needed to interface precisely with an existing threaded connection system without access to technical specifications. The translucent form required hollow internal geometry for light diffusion, while avoiding support removal issues that would compromise surface quality. Additionally, the double sided design required non mirrored geometry to maintain correct logo orientation on both faces.

Technical Execution
The threaded connection was reverse engineered through iterative test fitting to achieve accurate alignment and secure engagement with the base handle. The flame element was modeled as two unique halves rather than mirrored components to preserve proper logo orientation. To support hollow construction and clean internal surfaces, the design was divided into three printed components: two translucent flame shells and a threaded insert. The parts were assembled post print and bonded for durability, with color separation planned for a clear base, red flame structure, and contrasting logo detail.

Outcome
Seven fully assembled units were produced, validating repeatable fit, structural integrity, and consistent light diffusion. The project demonstrates interface driven design, thread compatibility development, modular additive manufacturing strategy, and small batch production capability.