Once I determined the design I would pursue, I started on the physical prototype. To create the skeleton of the flashlight, I made a simple cylinder in Fusion, exported it to Slicer, then printed the cross-sectional pieces out of 1/8" inch cardboard. This skeleton was originally intended to be a test, but I couldn't access the 3D Printers in a quick enough time to match the pace of the project. 

The cardboard pieces worked, but they kept falling apart. To hold the skeleton together, I wrapped the cylinder in duct-tape, then got to work applying clay.