CAD Exploded View of Final Product

The bike helmet task light developed throughout the course of this project utilizes three main components: the male rail, the female rail, and the light housing.

The first main component of the bike helmet task light is the male rail, which serves as the permanent mount on the bike helmet. The male rail has a curved bottom with a 7" radius of curvature to help match the curvature of bike helmets. The male rail is permanently attached to the helmet using a double-sided foam mounting tape. The male rail also includes a 3/8" diameter N52 grade magnet that functions as a locking feature when paired with the opposite facing magnet on the female rail. 

The second main component of the bike helmet task light is the female rail. The female rail functions as a removable component that slides in and out of the male rail and is secured into place via the magnet locking mechanism. The female rail is fixed to the light housing using a screw and washer at a pivot point where the screw insert is placed. A spring plunger is press-fitted into the front of the female rail which allows the housing to be adjusted with three different angular positions: -30, 0, and +30 degrees.

The last main component of the bike helmet task light is the light housing. The light housing is used to protect all of the electrical components. A screw and washer constrain the light housing to the female rail which allows it to be detachable from the helmet. The light housing is designed to accommodate the internal components which feature a rechargeable battery, one LED, and a small circuit board. The light housing is permanently sealed and contains silicon buttons and gaskets to meet water and dust proof requirements.