I am currently putting together a workshop on weapon/prop design that was requested by a local college, I decided to focus the workshop on lightsabers so hopefully it'll be fun for the students. The workshop is only 2 hours long so i cover the process in broad terms. My process is similar for most of my concept art work. I start off with research which I will continue to do throughout the development in order to inform my designs, I constantly refer back to the initial brief or my initial goals to make sure I am not going off on tangents. Ill start with initial designs trying to keep the ideas broad at the start and narrowing down as I continue the process; and only moving on to the next stage when I have a few design directions I am happy with. If I get to a later stage and the designs aren't working I simply go back and repeat the process until they are. I do a final when I feel my initial design goals and intentions have been met and are clearly communicated to the audience.