Personal Project

Proposal & research

So, when I was thinking about what I could create for my personal project, my thoughts immediately went to what I could use every day. In my personal opinion when you are given the chance for a open ended project, you should take full advantage and use the opportunity for something you could use. One of the fields I plan into looking into for my future after ASU is firearm design and/or development. I thought to myself as someone who carries a firearm, how can I optimize it to its fullest extent for me and others like me? So, I started thinking what I can that is achievable especially with what I learned in this course. I immediately thought of the attachments I have on my everyday carry. My light attached to my EDC has switches that are super stiff and short (well short for my short thumbs haha). This is where my research led to.

Research Question: How can a thumb-accessible control attachment for a rail-mounted flashlight improve comfort, reach, and ease of activation for users with limited thumb mobility or smaller hand sizes?

My solution will be to create 3-D printable extenders that easily replace the light switches.

The problem I am facing is specifically targeting the Surefire X300 line, as they are known to be stiffer and shorter than their competitions. And you might be asking why even choose that light, the light is exactly why to get it. It is also known for being one of the best and reliable handgun lights on the market. While there are extenders for the X300, they all cost between 30-50$ for small pieces of plastic. I wanted to make a free and reliable source for those that have access to a 3-D printer.

Here are just a couple posts I found from the same reddit thread about the topic.

The Process

I started the process with playing scenarios about the practicality of my project in my head. I wanted this to be able to work for everyone that owns the product, not just those who are facing my problem or have issues with hand mobility like arthritis. I had to think about how the attachments would be completely cohesive with the product. I wanted to make something that seemed like the company already had or the product at hand should already have came with. I would not want someone to put these extensions on without liking how they look. I began looking at the product itself.

After looking at the switches now, you may start thinking in your mind; "They don't look that short". Trust me they are and they are pretty stiff. I wear medium sized gloves, but even so my thumbs in my opinion are not that short. I might be coping though.

ExampleVid.mp4

Here's a better visual of what actually goes on when trying to flick the switch. This is also with my support hand all the way forward.

Another problem that I thought I had was making the attachments cohesive with holster use. No one will use the attachments if they are snagging on a holster or not even being able to insert their firearm in the holster they have.

So after hours of prototyping and messing around in Rhino I came up with the designs. I went with Rhino as the AME lounge's computers only have that program for 3D modeling, but it worked out as I used it before in classes previously. I kept them in line with the light and if my measurements are correct, they should fit perfectly to replace the switches on the actual light.

x300Attachments - Rhinoceros 7 Educational Lab License - [Perspective] 2026-05-07 14-47-19.mp4

I added grooves into the switches for better texture for the user. I want the user to never miss a flick or push in when trying to utilize the light. The main thing you can notice is that they will be noticeably longer then the OEM switches for better reach.

IMG_8410.MOV

IMG_8409.MOV

Here are the switches in action! Perfect for my stubby little thumbs.

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