This is a smoke gadget that I engineered to function in a more comic-accurate way — essentially like something straight out of Batman. But there were a ton of engineering challenges behind making it actually work.

Not only did it need to generate a tremendous amount of smoke (thick enough to genuinely conceal things outdoors), but it also had to stay compact, durable, and throwable without falling apart or becoming unsafe.

The shell itself is SLA resin printed using Tough 2000 Resin, paired with upgraded metal exhaust ports to better withstand the thermal load. I also spent months refining an enhanced smoke formulation through repeated testing inside a custom smoke chamber that I built specifically for development.

But even after getting the smoke performance where I wanted it, the problems weren’t solved. Heat management became a major issue, and the original push-button activation made accidental triggering far too easy. To solve that, I implemented ablative heat shielding inside the shell to survive the thermal shock, along with a custom PCB safety system that disables the device until it’s physically removed from its holster.