Table Lighter
product design, packaging, branding
Design Brief
Inspired by Dieter Rams' iconic Braun T2 lighter, I designed a modern reinterpretation using a standard Bic as the replaceable ignition source. Design criteria: elevate the lighter experience, enable self-production with removable insert system, ensure durability through material and construction choices.
Prototype V1: Concrete Casting
Initial prototypes used three-part 3D printed molds with removable Bic forms and custom stamped cork bases. The process validated overall dimensions and in-hand feel but revealed material limitations — Prototyping confirmed design direction but needed refinement.
Prototype V2: Refined Concrete Production
Redesigned silicone mold system with 3D-printed insert to accommodate Bic size variations. Achieved high surface finish and simplified production process. Sold direct-to-consumer and placed in Toronto independent retailers, with high-exposure TikTok content driving majority of sales. Repeat-customer feedback revealed concrete's fragility under impact — product pulled from market to redesign for durability.
Final Product
Shifted to CNC-machined aluminum for impact resistance and recyclability. Added mini size for smaller hands. Designed a new 3D-printed internal with a print-in-place magnetic button. Replaced stamped cork with custom wet-set debossed leather bases.
Iterated 50+ button variations to achieve tactile satisfaction — final magnetic mechanism provides addictive push-eject interaction. First batch of units sold to previous concrete lighter customers via direct email outreach. Production-ready files completed for Toronto CNC manufacturing.
Packaging Design
Unwrapping experience with zero glue — tuck tabs allow careful unraveling or a quick tear-through. Communicates product origin (Made in Toronto, Canada), manufacturer (All Conditions Studio), and quality positioning (“Crafted with pride”). Produced in-house using a printer/cutter system for rapid prototyping and small-batch production.
