
Road-Safety FLARE
The challenge was to design and fabricate a splash-proof electronic safety flare for roadside or other emergency applications.
A critical item for an emergency roadside kit is road flares. Traditional flares are pyrotechnic devices that burn brightly. Today, most people use battery-operated flares instead.
Project Brief
Requirments
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Basic Functionality can include any desired combination of flashing LEDs or neopixels. The goal is to achieve maximum visibility by using light pipes or strategically locating the light sources relative to clear portions of the casework.
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The casework can be fastened together with screws, but it must be sealed to be splashproof, achieving a rating of IP 65.
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Given that this product will be thrown in the back of a car, the unit must be designed to withstand a fair amount of abuse. Over molding of bumpers or protective elements is recommended. An elastomer protective case is also allowable.
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Students can elect to have the unit either be rechargeable or have replaceable batteries. In the case of the former, a weatherproof flap or plug will be required. In the latter case, the battery door will need to be sealed so that water can’t get in.
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All casework parts must be designed with an injection molding design in mind. Major features should have the necessary draft; wall thicknesses need to be realistic, no thick sections, and undercuts are only permissible if they can be achieved with a shut-off or a cam.
Design Ideation



Collapsible cone concept development and mockup



Cones get snapped to each other when pulled upwards.


Cones collapsed
Cones pulled
Exploded View


Circuit Playground
Replaceable Battery
Gaskit
LEDs




Flare illuminated without cone


Flare illuminated cone



Engineering Drawing


Project Outcome
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From this project I gain an understanding of the challenges and complexities of designing a product for a demanding use environment.
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