I engineered an aerodynamic smart bicycle light concept from initial ideation sketches through to production-ready design. Using CAD, I integrated internal optics, a rechargeable battery housing, and a weather-sealed silicone mounting bracket. I applied strict DFM principles for two-shot plastic injection molding and lens sonic welding, ensuring IP67 water resistance. The deliverable included dimensioned 2D engineering drawings with GD&T callouts and photorealistic renders showcasing dynamic LED beam pattern distribution