Project
Hex Puck Lights
Black + Decker Hex Puck under cabinet lighting: a master puck with satellite pucks and a low-profile, screwless clip-together housing.




Black + Decker Hex Puck Under Cabinet Lighting: Designed by Brian Barrett
Innovative Lighting Solution: Responding to the market dominated by generic puck lights, Brian developed the Hex Puck under cabinet lighting—a product that stands out for its ease of installation, cost-effectiveness, and manufacturing simplicity. This design remains one of Barrett's most esteemed creations, showcasing his ability to blend functionality with innovation.
Product Features:
Master Control Puck: Equipped with a proximity sensor for the standard version and an IR remote sensor for the color variant.
Satellite Pucks: Additional pucks synchronize effortlessly with the master control for unified lighting.
Design Ingenuity:
Low Profile Design: Achieved through creative engineering, including the innovative use of standard connectors.
Smart Connector Utilization: A standard mount connector ingeniously adapted as a mid-mount to reduce the puck's height.
Technical Highlights:
Pigtail Wires: Simplify the PCB, streamline production, and reduce BOM costs.
Screwless Housing: Showcases a clip-based assembly for the lens and body, eliminating the need for screws.
Proud Achievement in Manufacturing:
The Hex Puck's housing design is Barrett's pride, featuring a clever clip system that omits the need for mold slides—reducing tooling costs and enhancing the product's aesthetic. The design ensures all clips are hidden once assembled, showcasing a clean and sleek finish.
Product Legacy: The Hex Puck lighting series not only exemplifies Brian Barrett's design philosophy but also his strategic approach to product development. It highlights the importance of each choice in the process, from connectors to casing, and represents a significant achievement in creating a competitive, market-leading product.
Written up in
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- Cantilever Snap Fits: Ratios, Not EquationsOctober 18, 2026Snap fits are some of our favourite features to design. The maths is nice, but a handful of thickness ratios gets you most of the way, and which way the hook faces decides whether the mold is simple or painful.
- Fast Injection Molds in China: Tooling in 10 DaysOctober 16, 2026The standard story says a mold takes 30 days plus revisions. There is another way: 10-day injection molds, cheaper than regular tooling. Here is how they work, what the catch is, and when to use them.
- What 'landed cost' actually includesJune 9, 2026The factory quote is the number everyone fixates on — and it's often barely half of what a unit really costs to land on your dock. Here are the line items teams forget.
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