Using E-Waste, Recycled and Local Materials to Build Durable, Low-Cost Flashlights

Abstract

Access to reliable lighting remains a critical yet unmet need in many off-grid and low-income rural communities across the Global South. Meanwhile, the accelerating growth of electronic waste (e-waste) poses a mounting environmental challenge. Paradoxically, much of this discarded material-such as LEDs, lithium-ion batteries, and robust plastic housings-can be salvaged and repurposed into affordable, energy-efficient lighting devices. This paper examines the potential of transforming e-waste into durable flashlights, addressing both environmental and energy access gaps. The core concept is to address the dual challenges of energy poverty and e-waste accumulation by transforming discarded electronics into affordable, durable lighting solutions. Essential components like lithium-ion batteries, LEDs, and PCBs can be salvaged from common e-waste, including old mobile phones, radios, and broken flashlights. This recovered technology is then combined with readily available and recycled materials-including bamboo, PVC pipes, scrap plastic, and Aluminium foil-to create the flashlight's structure and optical elements, making the production process highly cost-effective and environmentally sustainable. The financial and technical feasibility is demonstrated by case studies from countries such as Kenya and Ghana, where models have been developed to produce flashlights at a fraction of the commercial cost, designed for local repairability. Furthermore, this process is organized into a localized ecosystem covering collection, assembly, sales, and servicing. This approach represents a powerful “waste-to-wealth” strategy that fosters micro-entrepreneurship, provides skill development for women and youth, and enhances community resilience, thereby contributing to global goals for clean energy and responsible consumption.