FTP led mechanical engineering of a multidisciplinary team which designed and developed a best in class FDA approved portable surgical headlight. It outperforms all of its competitors with brighter and whiter light, more comfortable fit, and longer battery life. FTP developed an innovative and patented system of exhausting the LED heat, which is essential for bright light, LED life, battery life, and safety. This exhaust system also reduces mass and improves comfort. Early in the product development FTP validated the new exhaust system with computational fluid dynamics (CFD). Its BOM is appoximately 100 pieces, and most of those parts are custom designed. Manufacturing processes include injecton molding, overmolding, machining, compression molding, and ultrasonic welding.