Modesto entrepreneur bearing the torch of a battery-free flashlight
By Marijke Rowland
Modesto Bee - August 30, 2009
 Dan Costa has seen the light.
In fact, he might just hold the future of flashlights in his hands.
The Modesto entrepreneur and 5.11 Tactical founder has just launched the Light for Life flashlight, which he and many of those who have used the product believe will change the hand-held lighting industry forever.
Those are big claims for what most people think of as a simple product. But the Light for Life's abilities might be even bigger. The flashlight is battery-free, recharges in 90 seconds, runs continuously for two hours and doesn't need replacement parts.
Costa said it is the last flashlight you will ever have to buy.
"You are going to buy one flashlight and hand it down to your kids," he said while showing it off last week in the Modesto headquarters of 5.11 Tactical, which makes tactical uniforms and gear favored by law enforcement.
"Certain technologies change the landscape, they change the way things are done. You're never going to go to a drawer where you have a bunch of flashlights and have to figure out which one works. This will always work."
That may sound like an inflated infomercial promise, but people who have tested and bought the product say seeing is believing.
"It sounds like snake oil, but the light works great," said Ripon police Sgt. Steve Merchant, whose Police Department was one of the first to have officers order the light after they saw it demonstrated six months ago.
About a dozen officers ordered it on the spot. Merchant has been using it as his primary on-the-job light for more than a week.
"I think this light will become the standard light for law enforcement. Police officers, we want equipment that works," he said. "We really have to risk our lives on a flashlight sometimes. We use our flashlights more than our guns, thank God."
The 11½-inch Light for Life, which hit store shelves Aug. 21, is initially being marketed to public safety officers only. At $169.99, it costs more than what the average consumer has considered paying for a flashlight.
'Priced too low' at $170?
But distributors such as Craig Stott at Modesto's Crescent Work & Outdoor supply store say consumers need to remember the purchase price is all they'll ever have to pay -- there are no replacement batteries, new LED bulbs or maintenance fees.
"I almost think it's priced too low," Stott said. "It's great for the consumer because they just buy one, but ironically for us retailers it means we're never going to see them again. They buy one and they are done."
Stott said the Light for Life is priced about $20 to $40 above the Streamlight SL20, the industry-standard flashlight for law enforcement. The Streamlight runs on rechargeable nickel cadmium batteries, which need to be replaced about every year and a half. The replacements cost $20 to $80 each.
While the Streamlight and Light for Life both run for two hours, Stott said, the Streamlight takes about eight hours to fully recharge compared with the Light for Life's 90 seconds.
At 16 ounces, the Light for Life is half as heavy but a lot brighter: 270 lumens at peak output compared with the Streamlight's 200 lumens. The current model has three modes: a 90-lumen general light, a 270-lumen spotlight and a strobe light.
Its body is made out of the same polymers used in handguns and has chipped concrete in testing. But because of its lightweight materials and one-piece design, it is water-resistant and floats.
The Light for Life also is a greener product. It contains no heavy metals and almost all of its parts are recyclable.
"As soon as I saw the light, I wanted to know how many I could buy," Stott said. "It sells itself. Whenever we brought them to show to a police department, we always end up going out to their patrol cars and charging it. The next thing we know we have a purchase order."
5.11 has had about 25,000 orders since it launched the product this month. Costa said distributors in all 85 countries served by 5.11 have purchased the flashlight.
The product's global launch is being met with rave reviews in Popular Science and Wired magazines and online tech sites Gizmodo and CNET.
What makes the Light for Life unique is its power source. Instead of traditional batteries, it uses new ultracapacitor technology developed by the Idaho-based company IVUS Energy Innovations.
Founded by former University of Idaho students David Alexander and Erik Cegnar, IVUS was created in 2005 to look for ways to develop and improve ultracapacitors. The technology, made from aluminum and carbon, has been in use since the 1970s.
Today they primarily are seen in hybrid vehicles, windmills and digital cameras.
IVUS Chief Executive Officer Alexander said his company was able to develop a system to improve the ultracapacitor's performance. While they always had been been good for sudden, intense charges, IVUS developed circuits that released the energy more efficiently.
Before harnessing the technology, an ultracapacitor worked like catching lightning in a bottle and releasing it just as quickly; now the bolt is released slowly and steadily.
In February 2008, Anderson brought flashlight prototypes to a trade show in Las Vegas. After asking around, he heard that 5.11 was the go-to company for public safety apparel and accessories.
"We stood outside the 5.11 booth and literally waited until Dan had five minutes between conversations," Anderson said. "And then we jumped in and introduced ourselves and the flashlight."
Inventor's claims unbelievable
Costa said he wasn't sure what to make of Anderson's claims.
"I was skeptical at first, too. I thought, 'OK, he is just trying to get my attention.' But then he had one in his car," Costa said. "The minute I saw what it could do, I said if we take this on we want the worldwide exclusive."
5.11 Tactical has an exclusive, worldwide licensing agreement with IVUS to use, distribute and market the technology in all hand-held lights.
The flashlights are being produced in China. All nonfactory direct orders are shipped to 5.11 warehouses in Modesto and La- throp for distribution.
A smaller, cheaper 8.5-inch model is being developed and should be on the market before the end of the year. Costa said specialized models with adjustable dimmers and hues are being developed for firefighters to use in smoky conditions.
While police and firefighters are its first adopters, tow truck drivers, pest inspectors, utility workers and outdoor enthusiasts have expressed interest.
Costa said the company won't start marketing the light to the public until next year after it has built its reputation among law enforcement. Then around Father's Day, it will bring it to everyone else.
"You might not buy one for yourself right now, but you'll get one for Dad," Costa said. "I want my mother to have one. For the rest of your life, you're never going to be without light."
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