Integrated Handle Light
THE PRODUCT
Acting as project leader in collaboration with electrical and software engineers, I developed this innovative integrated grill lighting solution for a major US gas grill manufacturer. This project demonstrates my ability to design consumer electronics from concept through production and how my iterative design process allows me to overcome new and interesting design challenges.
At project kickoff, all the client knew is that they wanted to light their grill in a new and interesting way. I had free range to propose and explore a range of ideas that had never been done before.
The final design was a grill light that was fully integrated into the existing handle, where the light emanates from the T-intersection between the handle and the grill lid.
MY CONTRIBUTIONS
- Brainstorming, ideation, and napkin sketching
- Research how light temperature affects the perception of food
- Testing various combinations of LEDs, light pipes, reflectors, and lenses to achieve the desired illumination on the grill surface
- Collaborating with electrical engineers and software developers to calculate battery life, specify desired board dimensions, design wiring harnesses. Also defining the product states and how they are impacted by user inputs
- SolidWorks development of injection molded, machined, and cut glass components
- Sourcing, assembling, and testing like-production prototype parts
- Final handoff documentation: detailed 3D CAD design, some schematic drawings, bill of materials, and assembly documentation
DESIGN CHALLENGES
- Product to withstand extremely hot temperatures up to 1000F (inside the grill) in the event of a grease fire
- Lighting had to be bright and even across the entire grill surface with no dead/hot spots
- Specify an array of batteries that would fit within the tube and satisfy our battery life requirements
- Light capture of LED had to be optimized to extend the battery life to meet our requirements
- Product to be IP66 rated against dust and water ingress
- Product to come in two sizes for a 3-burner and 4-burner gas grill
HOW IT WORKS
Light Path
Because the LED can only withstand 140°F we needed the space them away from the grill lid interface which could reach upwards of 1000°F in the event of a grease fire. To maintain brightness and optimize battery life, we used a TIR (total internal reflection) lens which captures all the light from the LED and focuses it into a beam which shines through a light pipe, at the end of the light pipe there is a double concave lens to spread the light out over the grill surface.
Assembly Optimization
By the final prototype, I refined the design so much that the entire assembly takes under 3 minutes to assemble.
Battery Sleeve
A battery sleeve easily allows the user to remove and replace the batteries that power the unit. It features a knurl on the end knob to help with grip. The rotation of the battery sleeve is poka-yoked so that the user is forced to install it correctly.
FINAL DESIGN
The design that I handed off is now in production and has sold over 1,000,000 units and growing as of Jan, 2026.
Our client went on to receive a patent for the innovative design my team created: US11333346B1
