AS Level Unit 2

2. - Front cover
- Contents page
3. Design Brief
4. Gantt Chart
5. Analysis Of Task
6. Initial Specification
7-8. Research Table
9. Interview With Client
10-11. Existing Designs
12. Inspirational ideas
13-15. Materials Testing
16. Alessi Background Information
17. Analysis of Alessi Products
18. Market Research
19. Primary Research
20. Disassembly Of Lamp
21. Available Manufacturing Processes
22. Analysis Of Research
23. Final Design Specification
24-28. Initial Ideas
29. Rankings
30. Pre-Bought Bulb Analysis & Anthropometrics
31. Sustainability
32-34. Developed Ideas
35-36. Card Modelling
37-38. Testing Housing Of Bulb
39. Interview With Client
40. Development Of Solution
41-42.Testing C.D Racks
43-44. Development Of Solution
45. Final Design
46. Exploded Drawing
47.Orthographic Drawing
48-49. Modelling: - Grey Card
- MDF
50. Interview With Client
51. Production Plan
52.Quality Control Assessment
53.Manufacturing Specification
51. Production Plan
52.Quality Control Assessment
53.Manufacturing Specification
54-55. CAM: - MDF Base
- Acrylic Components
56-59. Testing: - Stationary Holder
- Bulb Holder
- Polymer Diffuser
- C.D Rack
60-62. Manufacturing
63. Final Images
64. Modifications
65-67. Evaluation: - Testing Against Specification
- General Evaluation
- Client Evaluation
68. Industrial Manufacture
69. Location Of Product
70. Recommendations

3. One of my local D.I.Y establishments are looking
to renew their overall look and have requested
for a new modern yet simplistic lamp relating to
the existing products of Alessi. New design ideas
are needed to compete with the existing market,
which are primarily targeting younger
professionals and students. The establishment
believes that by bringing this new innovative
design into the current market, will benefit
greatly into generating income.
The new design ideas will therefore have to be
more contemporary with the existing
modernistic designs and also to appeal to a
wider range of customers than just students and
the younger generation. This will therefore
increase sales and have a higher competition
rate within the current market.
Alessi based products are simplistic yet
innovative and modern which are
contemporary with existing designs. Instead of
just serving its purpose as a lamp it may also
be multi-functional and contain storage units.
Maybe also to consist of replaceable products,
which again will increase the intended target
audience and adapt to numerous genders and
understandably more income.
Whilst still pursuing in a modernistic and
Alessi based design, the product will also be
composed of a more professionalised
appearance. The product will be aesthetically
and ergonomically designed around the
majority of the target audience, as this will
play a large role into attracting my specific
range of customers.
The image used in the background is of which the final manufactured product will be
situated. This is an example of a primary research image of my local D.I.Y establishment.

4. Here is my Gantt chart, which will help me plan the various stages throughout my project. This will help also in organising time sufficiently
in order to complete set tasks and relevant research. Essentially just a planning aid but will be most effective in keeping track of my
progress and if I need to work faster.
With the specific sheets and research mentioned down the left hand side of the chart and moths/ weeks situated across the top it makes
it much clearer than when looking back to my contents list. Designed and made on Microsoft Excel, a spreadsheet program initially
designed for this type of organisation and planning facilities.
When relating back to the predicted time line of my progress, my
manufacturing process unexpectedly took longer than originally
planned and had to adapt to the work rate. Therefore enabling me
to maintain my work rate and not fall behind.
However I think that I stuck to the overall
outline of the work plan and this really
helped me to categorise my work rate. This
therefore enabled me to stretch out the time
of which I had for the production and
modelling processes.

5. For the product that I will be designing I will be using the most
suitable materials, but at the same time take into account the maximum
quality finish and also to overall maximise profits. The overall finished
product will be to high standard and therefore will cost approximately
in between £10-£20. This will be taking into account the manufacturing
costs of the product too, as the product will need to be most cost
effective for what the intended target audience will be purchasing.
Therefore as the product is aimed at students/ young professionals the
cost needs to be as low as possible.
The size and weight of my lamp will depend on my further design
developments, and also in particular my extensive use of materials
chosen. Another key factor to conclude my overall size and weight for
my lamp would be the ergonomics to adapt to the surroundings and also
to be sturdy enough to withstand any knocks or to prevent any
unnecessary damage towards the product. Also to refer what I mentioned
previously the lamp has to be big enough to serve as a multifunctional
product and to house the bulb inside easily.
Due to my design brief my product will be in aid of improving the
establishments image within the this products market. Within this
target, the product will be mainly aimed towards students and young
professionals. Therefore the design will have to be modern with
contemporary design which will grab the intended customers and
maximise sales.
The product will be successful if it meets the required measurements
and standards of its intended purpose. The overall finish of the
product will highly important as the product will have to adapt to
its Alessi background. Another important factor would be the
functionality and ergonomics of the lamp so its easier to use for
the customers. Along with this the price will have to be convenient
enough to entice the intended target audience.
Environmental factors and the use of sustainable materials will
have to be highly considered when designing and manufacturing my
lamp. Within the making of my product, recycled materials will be
used whenever possible overall decreasing the cost of the product.
The main use of recyclable materials will be concentrated on the
information include within the lamp.
The possible materials used to make my lamp will be MDF
(Medium-Density Fireboard), will may play a large role in to the
production of the main body of the lamp, and by using this specific
material I am able to produce a high quality finish if deciding to add
paint. Another key material to consider would be (continuous cast)
acrylic to reduce cost as its a least expensive process, its softer,
and can be shaped easier. To maintain a good quality finish for the
base of the lamp possible material such as Mahogany Veneer, which
is a high priced material but will make the product more enticing.
By using computer based software, such as CAD CAM and other
similar computer design software's the product will be designed and
cut sufficiently, accurately with also upholding a high quality
finish. With other possible material choices, such as; HIPS or
acrylic, manufacturing techniques like vacuum forming and
injection moulding will be a more productive solution to
use in mass production. Other requirements such as general
safety features will have to be considered with the product
being electrical.
At the end of its life the product will be designed so that when
coming to dispose of the product it can be easily disassembled
and therefore easier to recycle. The average life span of a lamp
such as this would be high compared to an ordinary lamp, as the bulb is a
low frequency bulb using less energy.

6. My lamp will be specifically aimed at the younger generation, whether being students or
even young professionals. Statistically ranging from 16 – 30 years of age. The product
will be designed so that it can be adapted to both genders. So by aiming my product at
this particular target market the design will have to be contemporary and consist of
modernistic colour schemes, such as; mahogany, beige, silver and possibly black.
The most obvious function will to be serve its purpose as a desk lamp, but rather than
just consist of just one function maybe the product can be multi-functional. This may
comprise of having storage devices which could be used to accommodate office
materials/stationary. Also the lamp may be composed of some sort of novelty accessory
also to add humour to the product which most Alessi products have been designed
around.
The size and weight of my product will be determined mostly by the designated
environment of which I have chosen to design my product around. As it will be mainly
used by young professionals the lamp will understandably be situated the majority of
the time on some sort of desk or working area. The lamp will be have to large enough
to ensure it houses the bulb with ease and also to have spare storage space to
encompass any other additional features.
The cost of the product will not be too high as it is this particular factor of which
most customers are thrown by, but at a suitable price to generate enough profit for
the establishment and with – hold a sense of good quality item that is manufactured
to a high standard. By using specific materials which are mostly sustainable and can
be manufactured with ease, this will overall reduce waste and reduce any
unnecessary costs.
The aesthetics and material choices towards the production of the product has to be
suitable for its main purpose, acting as a lamp in a professional, formal environment,
the aesthetics of the lamp design has also importantly follow the style of Alessi. The
aesthetics therefore has to be vivid and original. The way of which the product is
presented will play a large role in catching the customers attention among other
existing designs. This will be achieved through aspects, such as; the materials used
(polypropylene, acrylic, and various hardwoods. The colours will also have to be
contemporary in order to achieve a subtle colour scheme.
This factor will need to be highly considered into the making of the product as
this aspect is sometimes overlooked and resulting sometimes offence to certain
religions and ethical backgrounds. Any un-intentional offence may cause upset
towards the product, which will decrease sales accordingly.
The product will have to be suitable for nearly almost indoor environments,
which will cause no extensive problems in choosing a suitable space for the
product. This will be concluded through maybe material testing of the product
in different work spaces and also testing upon different material surfaces. By
further testing towards this aspect of the design specification towards the
product, I can then adjust the products material choices.
The way in which the product is manufactured and overall packaged will have
numerous impacts on how the lamp will function and perform as a lamp.
Sufficient manufacturing processes will need to be overviewed as this will
determine the quantity and quality of my new design. Another key feature into
promoting the product is understandably is the packaging as this will promote
and advertise the product and will also set the first impression upon the
product. The instruction manual for assembly should be made from recycled
materials contributing to environmental factors.
The accumulation of all of these key aspects will give me a
further insight into what needs to be considered when
coming to the designing of my lamp. The key information
also mentioned above will have help me to consider
manufacturing techniques and how to market the product
sufficiently, but most importantly how I could possibly
reduce any impacts I may have on the environment.

7. What do I need to find out? Where can I look? How I will use the information?
I will need to firstly accumulate different
materials of which I will use to make my
product.
I can test different materials around
colleges weighing up the advantages of
each material.
I could also collect materials from nearby
establishments, such as; Mamby’s, IKEA,
and Homebase.
With the information accumulated from the
numerous resources, I will then go on to
compare the advantages and disadvantages
taking into account the average cost of each
one.
Size of bulb which will therefore inflict
upon the size and shape of the overall
design.
My college has already pre- bought the
bulb, so I can measure the dimensions so
that the bulb is embossed securely In the
overall design.
I will therefore from the dimensions of the
bulb I will then conclude the final
measurements of the overall lamp.
I need to evaluate previous Alessi designs
and relate to my initial ideas and see if
there is a relevant comparison.
I can research on the internet viewing
images of previous designs and also collect
images through books.
I will relate back to numerous Alessi designs
and try to incorporate it into my own lamp
design.
What manufacturing processes will be
needed to mass produce the product.
I can research existing lamp designs with
similar material properties and find the
most resourceful and sustainable process
is. This will be concluded from resources,
such as; the internet, and Alessi based
lamp designs.
From my research I will conclude the most
suitable manufacturing process which will
prove to be much quicker and more
sufficient.
I need to research further into my target
audience and most popular lamp designs
within that specific age range.
I can collect numerous amounts of
research, the majority coming from some
form of questionnaires, and also to look
around in existing establishments.
This will therefore help to mould the design
around the target audience and this will
overall help to boost sales within the
establishment.
Possible colours used within the product. I have recently visited a nearby D.I.Y
establishment and have collected
numerous colour wheels, and also
information on what colour compliments
the materials used within the product.
Through receiving this useful information I
will therefore be able to plan my colour
schemes effectively and adequately, which
will make my lamp more attractive when
compared to other existing designs.

8. What do I need to find out? Where can I look? How I will use the information?
Survey/ Questionnaire This research can be carried out in
numerous different ways, such as;
formally/verbally interacting with different
people. A questionnaire which may be
placed online, and also a questionnaire or
survey that can be handed out.
This research will be carried out to
accumulate the opinions of numerous
people regarding the certain aspects of my
initial ideas for my product. This will then
give me a better understanding of what
the target market would like to see in my
new innovative design.
Interview with client I will gather information directly and
effectively straight from the client, which
will hopefully categorise the different
factors of which would be included within
the product as well as house the energy
saving light bulb purchased from IKEA.
With specific requirements set and
directed from the client I will be able to
comprise my overall product of his/hers
needs. This will include gathering
information on aesthetically how the
product should look and even possibly
material choices.
Finishes I will complete intensive research online
mostly into websites, which specialize in
information about the numerous types of
finishes. This hopefully aid my decision on
what finish is most attractive towards my
final design idea.
I plan to gather images and useful
annotations which will help me to a
conclusive decision on which I will use for
my product. Then once all finishes have
been accumulated I will evaluate their
effectiveness and the offer It can provide
to the value of money.

9. Firstly I would like to ask, if you have any problems with storage
Which can be addressed through a multi-functional lamp?
“Most of the space on my desk consists of numerous types of storage
devices for many different types of stationary. It would be a good idea
to incorporate different storage space within a lamp, it would be most
sufficient for students, such as myself.”
For a lamp which you would normally associate with being
suitable for a desk or office type lamp, what overall size would
you recommend?
“The lamp of which I have recently purchased for my desk has proven
to be quite manoeuvrable but yet takes up the majority of my work
space with no other purposes to offer than just proficient lighting.”
If choosing from a wide range of lamp designs in a typical high
street establishment what features would best attract you in
purchasing the product?
“I would be more edged towards with a lamp that has a contemporary
design and consist of modernistic colours. Something which you
mentioned earlier about a multi-purpose lamp would also attract me
into buying a design with similar characteristics.”
When coming to choosing which product is best to purchase,
does any sustainability or environmental factors play any role in
helping you decide?
“I would like to say it does, but it wouldn’t be the deciding factor in
whether I would purchase the item or not. However when comparing
it to similar products of a good quality finish I would then be
persuaded by what material choices were made and what
environmental factors both products with hold.”
Lastly, are there any finishes or colour schemes you would like to see
which could be taken into account when coming to design my new
product?
“Well, colour schemes are very important in keeping with the contemporary
designs and also the finishes which also compliment specific colours used. So,
it would be different to have something which would uphold a sense of a
modernistic colour scheme yet consist of vibrant material finishes.”
With key information required from my client, this will
therefore provide me with a clearer picture of what
customers would like to see on the market in regards to
lighting.
Through this information it will be a large benefaction
as these key points will give me rough guide lines when
accumulating initial ideas. In conjunction with the
clients feedback I will incorporate this and will help me
with how I should pursue the designing stages of my
project.

10. My reason for choosing this product is the simplicity and modern contemporary
design, but still just as effective when compared to similar products. The average
cost for products similar to this, range in between £7 - £12, which in my opinion is
a little over priced, which may unfortunately decrease sales. The typical person
who would be interested in purchasing the product would be a student or maybe
an office accessory, so therefore a wide target audience. As mentioned above the
product will be mostly used by someone who works anywhere with a desk in front
of them, which is an extremely large gap regarding the designers market. This
particular product that I have chosen is far from eco-friendly and when coming
to dispose of the product special attention is required.
Key features:
- Slim and lightweight: easy to
place in small spaces and move to
wherever you need light.
- Adjustable arm for easy directing
of light.
- Uses LEDs, which consume up to
85% less energy and last 20 times
longer than incandescent bulbs.
Package measurement and weight
Width: 12 cm
Height: 6 cm
Length: 16 cm
Weight: 0.4 kg
Product description
Arm: Steel, Paint
Shade: Aluminium, Paint
Base: ABS plastic
Weight: EVA plastic, Cast iron
Much like the product above this too has a sense of simplicity towards
its overall design. The average cost for products similar to this, range
between £9 - £14. The typical person who would consider buying this
product would be parents for the young children. The product has
been designed around children of a young age, so understandably the
safety requirements for this product are very high. Again like the
product above due to the choice of material used within the making of
the product special care is needed in disposing of it.
Key features:
Recommended for ages from 3 years.
Shines 4-5 hours with the battery fully charged.
Transformer/charger included.
Light diodes are not replaceable; diode life approx.
50,000 hours.
1 rechargeable AAA 3.6V NiMH battery is included.
The light changes colour - press switch to lock it at one
colour.
Product description
Lamp housing: Polypropylene plastic
Cover: Silicone rubber, Silicone resin paint
Package measurement and weight
Packages: 1
Weight: 0.3 kg
Key features
- Adjustable arm and head for easy
directing of light.
- Halogen bulb GU10 35W reflector
Package measurement and weight
Packages: 1
Article Number : 101.707.04
Weight : 4.1 kg
Quantity 1
Product description
Arm: Aluminium, Clear lacquer
Base: Steel, Powder coating
Joint: Aluminium, Acrylic paint
Shade: Aluminium, Powder coating
I like the design of this product as it with holds contemporary design, and
Has been made around ergonomically around the customers. With its easy
manoeuvrable arm to adjust the direction of light, this is the key aspect of
which why this particular product is so popular. The average cost of a
product much similar to this would be in between £9 - £25, which from
something which may look so simplistic may be a price too much to pay.
The main target audience in my opinion for this product would be
someone, such as; young professionals and students, due to the products
office characteristics. This again contains materials which may need
special attention when disposing of but also consist of easily recyclable
materials if dis-assembled correctly.

11. Here are some more existing designs which relate closely to my
first initial design of which to base my lamp around. These
designs will be a large benefactor into helping me consider which
materials will be suitable to choose when designing the product.
I like this lamp design as this is what I will
be basing my design stages around. With
the product being multi-functional
rather than just have storage units, this
design consists of a built in docking
station which would also be a great
concept to and accessory to also include.
With this unique design, it will be sure to catch the intended target audiences
attention. Along with the products vibrant colour scheme, and numerous
customisation accessories. Designs such as this will be effective as they uphold the
capability of being aimed at different age ranges and most importantly both
genders, as you can rearrange the products appearance.
Here is another example of an existing
jukebox lamp, which when compared to
the image situated top left has completely
different design aspects. This designs in
composed off mainly MDF with acrylic and
other plastics to brighten up the basic
shape of the jukebox.
With the different materials embossed
within the product it contrasts greatly
and defines each key object and layer
upon the jukebox.
This is another similar deign in terms of the
base of the lamp, however what
differentiates this design from the one
above this has incorporated a lamp shade.
The lamp shade acts as an accessory, which
can generate profit due to its customization
aspects.
The only difference between this existing
model and the initial designs I have to
manufacturing my product is that the light
is congregated within the lamp shade and
other materials used.
I have chosen this innovative lamp design
as this incorporates one or more functions
within the lamps purpose, which is a very
unique design.
With the lamp consisting of more than
one purpose, it has a more contemporary
feel towards the product and in my
opinion has a greater chance of sales
when compared to other existing designs.
By what seems to be acrylic which has
surrounded the interior lighting, this
feature has a great impact on the overall
finish and is something of which I can take
into account when designing my lamp.
This lamp has unique properties,
and design aspects similar to that
of the product situated in the
middle/ left of the page.
This design as you can see has a
lamp shade which I too may have
to consider in terms of directing
light onto and towards the
working area.
As well as the basic jukebox shape
the product also has unique
decorative designs throughout,
which I could use make from vinyl
which will provide a good quality
finish.

12. Here I have accumulated numerous different
images which will have an impact on my
initial designs for my lamp.
This may include the products shape, design
aspects, finishes, and other relative
decorative features which I may use.

13. Testing of materials is a vital factor to consider when coming to the designing and manufacturing of the product, whether considering
into mass or one-off production. This will provide me with key information regarding the aesthetics and ergonomics of the product
and most importantly how successful the finished product will be. Within my lamp I would possibly like to consider the use a range of
different materials, and most importantly within the design stages describe how the different materials compliment one another
when incorporated into a specific design. Testing a wide range of materials will provide me with key aspects, such as; strength,
durability, easy to manipulate, density, overall costs and also finishes which could be applied when assembled.
Material Uses Properties Advantages Disadvantages One Off Production
Manufacturing
Process
How can I use it in my
lamp project?
Image of
material
Acrylic
Poly(methyl
methacrylate)
 PMMA was used in
laserdisc optical
media. (CD’s and
DVDs)
 Display Signs
 Roof Lights
 Machine Guards
 Baths
 Trade name is
Perspex
 Glass like
transparency
or opaque,
which can be
coloured with
pigments
 Hard wearing,
but will shatter
if treated
roughly
The most important
advantage of this
material is that it can
be manipulated easily.
Acrylic can come in
numerous different
colours and thickness,
which will prove useful
when designing my
lamp. Acrylic looks
deceptively fragile, but
it can support a great
deal of weight. The
flexibility of the
material also makes it
comparatively easy to
duplicate standard
pieces.
Scratch Resistant: This
is the main
disadvantage of
acrylic, it scratches
easier than glass. The
way around this,
however is to rub a
good grade of paste
wax into the acrylic.
This will make the
scratches 'disappear'
and the material will
appear to be brand
new.
For This particular
material, I situated the
PVC into a fan
circulated oven. This
will allow the acrylic to
be flexible long enough
so I can sufficiently
manipulate it into the
desired shape.
Due to the materials
manipulative properties,
I can incorporate this
material into my design
quite easily. This can be
considered when
debating on which
material to use for
holding stationary and
other various storage
items.
Medium Density
Fibreboard
(MDF)
 It may be used to
make:
 display cabinets
 wall-panels
 storage units.
 It is made up of
fine particles
and therefore
does not have
an easily
recognisable
surface grain.
- Can be
obtained in
natural colour
in various
thicknesses or
self coloured.
MDF does not contain
knots or rings, making
it more uniform than
natural woods during
cutting and in service.
MDF may be dowelled
together and
traditional woodwork
joints may even be cut.
MDF may be glued
together with PVA
wood glue. Oil, water-
based paints and
varnishes may be used
on MDF. Veneers and
laminates may also be
used to finish MDF
Like natural wood,
MDF may split when
woodscrews are
installed without pilot
holes, and MDF may
be glued, doweled or
laminated, but
smooth-shank nails do
not hold well.
For the testing of MDF,
I precisely marked out
a comb join of which I
would cut and
carefully place
together. Firstly divide
the edge of both
pieces of MDF into
three by using a pencil
and ruler, and then
calculating the
thickness of the
material so I knew how
deep to cut into the
material. Once cut with
a coping saw, I then
sanded down the
joints so they slotted
perfectly into position.
MDF as you can see is
not a very attractive
material to use, however
this material is a good
choice for the base of
my lamp, as its sturdy
and once set into place
can withstand any
unwanted knocks. This
could be then finished
with Mahogany Veneer
to express a more
professionalised
appearance. This
material would also be
considered when
designing the holder for
the actual bulb within
the base of the lamp.

14. Material Uses Properties Advantages Disadvantages One Off Production
Manufacturing
Process
How can I use it in
my lamp project?
Image of material
High Impact
Polystyrene
(HIPS)
 Used as displays,
POP graphics,
signs, trans
lights, tags and
cards.
 High Impact
Polystyrene can
be fabricated
and is easily
thermoformed
and is typically
used for
handling-trays
which
accommodate
lightweight
product.
HIPS - High Impact
Polystyrene, it is a
tough, rigid plastic
material with high
impact strength which
can be guillotined,
punched, routered or
sawn easily, and is
readily available in a
wide variety of colours.
Used widely for toys,
packaging, signs,
kicking plates, display
and point of sale.
High Impact Polystyrene
(HIPS) offers a
consistent, easily printed
matte surface for either
one or two sided
printing applications.
This polystyrene
product, available in
HIPS sheet or roll stock
form, is especially
suitable for Lithographic
or Flexographic printing.
HIPS sheets has marginal
resistance to impact and
tearing, although it can
be modified with a
rubber additive to
improve its durability.
The disadvantages of
this material is that it
reduces electrical
properties.
It has minimal
transparency and also
the material increases
moisture absorption.
With this particular
material, I placed an
MDF wooden mould
which consists of a
unique shape into a
vacuum former.
The wooden mould is
then lowered whilst a
sheet of HIPS is
situated above. Then
once the material is
heated and made
more flexible , the
wooden mould is then
raised and embossed
within the plastic, and
then excess air is
removed and moulds
around sufficiently.
For my Alessi based
lamp, I could possibly
consider this material
as my overall base,
however this
wouldn’t be as sturdy
and lack in strength
when compared to
materials, such as
MDF. Another
possible feature of
which I could use this
material for would be
to construct some
sort of additional
draws which would
contain some sort of
stationary.
poly(vinyl
chloride)
 Because of its
water resistance
it's used to make
raincoats and
shower curtains
 Structurally, PVC is
a vinyl polymer.
 PVC is commonly
used as the
insulation on
electric wires; the
plastic used for
this purpose needs
to be plasticized.
Advantages of this
product include; the
material is extremely
lightweight when
compared to similar
plastics. The material is
flexible and therefore
easy to bend and shape,
useful for an Alessi
based lamp design. The
material is long lasting as
it has a high tolerance in
regards to corrosion.
Disadvantages include;
this material when
mishandled can crack
easily and cracks at high
pressures also.
Also the material is
highly sensitive to UV
and oxidative
degradation.
To successfully
manufacture this
plastic, I situated the
PVC into a fan
circulated oven which
can reach
temperatures of 400
degrees. With the
temperature building
from around 180
degrees Celsius
onwards, the material
will be manipulative
enough when left
around 30-40 seconds.
Whilst still malleable,
the material can be
easily shaped creating
unique designs and
then hardens rapidly
when cooled.
PVC in my lamp
project would highly
be considered when
initially designing the
decorative aspects of
the lamp. Such as;
curved surfaces
which consist of a
sharp edge which
then require a
decorative finish,
allowing a better
finish in regards of
texture and also
looks.

15. Material Uses Properties Advantages Disadvantages One Off
Production
Manufacturing
Process
How can I use it in
my lamp project?
Image of material
Flexible Plywood  Flexible Plywood
are used to create
strong and
attractive curved
structures and
surfaces for
exhibitions, film
and TV sets and a
variety of other
decorative and
design applications
 This flexible
plywood panel is
commonly called
'bendy plywood'
or 'flexiply', and
is used
extensively in
furniture and
shop fitting,
wherever curves
are desirable,
demanding of a
panel that is
extremely
flexible.
Bendy plywood is more
convenient and much
lower in cost than
premade wooden forms,
as this flexible plywood
will hold its shape once
it is glued, laminated or
veneered. This ability
offers significant time
savings, as curves &
circular designs can be
produced using flexible
plywood without the
need for a structural
skeleton or special
support.
A major disadvantage
of this particular
material is that
during the
manipulation process
the material which
you can hear starts to
split and crack ,
which overall
weakens the material
and may decrease
future sturdiness to
the overall product.
Within my material
testing for this
material, it consisted
of a curved piece of;
MDF, a thin piece of
Flexible Plywood,
PVA, tacks and a
hammer.
I first placed the thin
strip of flexible
plywood onto the
MDF and applied a
layer of PVA,
however the
adhesive is not
strong enough to
withhold the
plywood's shape, so
tacks are therefore
hammered in to
secure the plywood's
shape around the
MDF.
This particular
material as you can
see demonstrated to
the right, can also be
incorporated into the
structural base of the
lamp. Especially
when certain areas of
the lamp, much like
Alessi designer
lamps, require
bendy/ curvy
surfaces.

16. Alessi was founded in 1921 to produce crafted products in metal for eating and drinking, by
Giovanni Alessi. In 1935, Carlo Alessi (born 1916), son of Giovanni, was named chief designer. In
1945 he ascended to chief executive and designed the coffee service Bombé, an industrial piece
manufactured in four sizes. That same year Carlo's younger brother, Ettore Alessi, joined the
company as a technician.
By the 1980s, Alberto Alessi took over the management of Alessi (which he still does today) and
launched the Alessi company into the design decade through collaborations with designers and
architects such as Alessandro Mendini, Ettore Sottsass, Richard Sapper, and Achille Castiglioni. In
2004 Alessi launched the Tea & Coffee Towers, with a new generation of architects such as Wiel
Arets, Zaha Hadid, Toyo Ito, Tom Kovac, Greg Lynn, MVRDV, Jean Nouvel, and UN Studio.
Among the best known of the company's product range are Richard Sapper's kettle with a two-
tonAnselmo Vitale and Luigi Massoni began to be employed on a consultancy basis. After the
Second World War the company increasingly turned to stainless steel instead of the nickel silver
and brass that had characterized its earlier products. Though still respecting the craft traditions
that were such a key aspect of design innovation and practice in post-war Italian consumer
goods, the company also expanded its scale of production to what may be seen as medium-
sized. In 1970 Alberto Alessi Anghini became general manager of the company and has been
responsible for the company's increasing commercial and stylistic prominence for more than 30
years.
e whistle, Michael Graves' kettle with the bird shaped whistle, Massimo Giacon's Mr Suicide,
and Philippe Starcks playful three-legged Juicy Salif citrus squeezer.
In 2006, the company reclassified its products under three lines: A di Alessi (products with
lower price points), Alessi (the main collection) and Officina Alessi (the most experimental and
limited edition pieces). 2006 also saw the opening of Alessi's first New York City flagship store
in SoHo.

17. The aesthetics of this unique Alessi designed lamp is that the features of the lamp, such as the
decorative overlay fits in well with the modern contemporary designs. The colour choice of the
products also compliment their modernised features.
The cost range of products similar to these would be approximately between £30-£50, depending
on which size you would prefer to purchase. With the price range set so high for something at first
sight which seems so basic might have an effect on the overall sales of the product.
The particular age range for this lamp would be someone of the ages of 20-40 years old directing it at
a specific age range. This is also due to the theme that the two products uphold in terms of
decoration, as this would be a good feature to have present at a wedding or an anniversary.
As mentioned previously the product could be used at a wedding reception, or an anniversary. The
product however does require special attention and care when coming to dispose of, but however will
be a good feature to use in a crowded environment as the bulb is not fully exposed minimalizing the
risk of any burns.
The safety features of this product as with any other Alessi based design withholds safety precautions
when progressing through the design stages of the product, and also to fit in with the Alessi based
theme. With no sharp edges or no hard materials used the product has a high safety rating.
The sizes of these particular products will vary in height and width, this particular model however is
70cm in height, and 15cm in width. This is the biggest of the models which you can purchase and the
smallest would be 20cm in height and 4cm in width.
The main function of the lamp is obviously direct a significant amount of light onto the designated
area, but however with the lamp being subject to customization features it can also portray different
coloured lighting, again submitting the product into different themes.
The material used with these two products are the stem which runs through the centre of the product
providing support and sturdiness, which is made out of steel. The outside decorative material forming
the dress and shirt, are made from silk, which is an expensive material.

18. 0
2
4
6
8
10
15- 16-19 20-25 26+
Classic/
Traditional
Quirky/
Colourful
Modern/
Minimalist
0 2 4 6 8 10
Function > Appearance
Appearance > Function
Both equal
Monochrome
Neutral/
Pastel
Hot/ Cold
Various
Market research is a vital factor which has been
considered into the designing and specifically
the ergonomics of the lamp. I have composed a
series of questions that should hopefully give
me an overall grasp of what the consumers are
currently interested in and the different aspects
of which I need to pay more attention to.
These are a few examples of how I can visually
representing accumulated data from my
questionnaire. This is so I can summarise
comments and make overall important
judgements on design features of the lamp.
In question 4, this is high advantage due to the
consumers opting for Modernistic and colourful
designs, much like Alessi products.

19. These are a collection of images taken from local hardware
establishments, which consist of; B&Q, Mambys, and BHS.
As you can see I have accumulated a wide variety of lamps
designs of which I can take inspiration from when reaching
the initial design ideas stages for my project. With having a
wider range of products I have now relevant quantities of
information of the different design aspects of which the
current market consists of.

20. I partially dismantled my lamp from home, which as you can see is comprised of a very sophisticated
design, as to give me a greater understanding of how all of the components work along side each
other, and the requirements needed in order to manufacture an existing lamp. This area of research
also helped me to grasp the wide use of various materials .
With the lamp being a successful ergonomically designed lamp, it also features an adjustable stem of
which has been incorporated to suit the requirements of the customers.
There are three main parts to the lamp I have disassembled, which consist of; The base, stem, and
head where the bulb is situated.
The base of the lamp has the main function of switching the light on and off, with a simple yet
innovative design which is user friendly. The button is a dome shape made from H.I.P.S, which can be
easily be incorporated into my own design as this can be easily be manufactured using the vacuum
former.
The stem of the lamp is responsible for conducting electricity to the head of the lamp where the bulb
is situated, this is made from either Aluminium or steel. Whilst carrying out that job it has also has
two others functions, which are; to provide additional support to he product, and also to be able to
manoeuvre providing a fully rotational 360 degree spin, which in a busy working environment is very
useful. It can also be extended to an additional height from, 30cm up to 50 cm.
The last component of my lamp is the head. This is where the bulb is housed and provides light in the
designated area of the user, this is compatible due to the rotational properties of which the head can
perform. It is capable of rotating 360 degrees horizontally, and rotating 180 degrees vertically,
providing light in all of the users work space. The bulb protector and diffuser in some regards is made
from a transparent piece of acrylic which is lightweight and provides an easy surface to clean.

21. The laser cutter can produce profiles of much finer detail
when comparing to hand cut objects, such as MDF. The
width of cut is much narrower when compared to similar
machines, like the plasma cutter, producing less waste
material. The laser cutter can be used for the majority of
my product to ensure all components are to a constant
quality, and due to the wide range of materials the laser
cutting can be performed on. The laser cutter can also be
used for engraving. The amount of emitted by the laser is
variable by controlling the power output, and a finer
output by also changing the speed of which the laser
travels over the material.
The vacuum former is used to shape sheet based
polymers around a mould, which is normally made
of a wood. The vacuum former heats the polymer
just above its softening point and held securely in
place above the wooden mould. Then the polymer
is shaped around the mould and the air that is still
present between the mould and polymer is
extracted by the vacuum achieving a greater
detailed finish. This manufacturing process could
be easily used whenever a complicated design is
required and the most suitable choice of material
would be a plastic.
The pillar drill displayed to the left is a useful piece of machinery as it enables you to
acquire precise piercing holes within selected wood, whether it be quite thick such as,
Walnut or even MDF. The drill itself is easily changeable to different thicknesses which
provides numerous different radius’, useful when selecting the right sixe hole of which you
may desire. The leaver consists of a much larger perpendicular distance from the centre of
rotation allowing ease of turning to lower the drill into the wood.
Modern machines such as Boxford’s A3 HSRi²
Router can be used to manufacture products
designed in software such as Pro DESKTOP,
with a combination of accuracy and speed.
The router can shape a variety of materials
including Perspex, MDF and model board. 3D
modelling brings modern design and
manufacturing technology into the college
workshop. This type of machinery will be
particularly useful when designing
components such as my C.D rack.
Roland cutters produce crisp, eye-catching graphics with
speed and precision. Applications include vehicle
graphics, signs, decals, labels, stencils, pin striping, paint
protection film, logos.
The speed and precision of the GX-24 digital cutter is to
be admired. It uses a digital servomotor to achieve
maximum accuracy and cutting speeds of up to
500mm/s. It also features a curve-smoothing function
that allows precise cutting, even at high speeds. The
result is faster production and more professional looking
graphics.

22. This aspect of my research plays a vital role in giving me a further
indication what exactly my research should initially be based around.
It also provided me with the relevant information I needed in
understanding what the specific requirements are of the target
audience. The information accumulated indicates my specific
requirements for my lamp and important design aspect which need to
be tested against throughout the designing and manufacturing
processes.
The disassembly process of a lamp aloud me to gain a visual
understanding of how the different components work inside an everyday
lamp. This includes; the housing of the bulb, how the products
functionality compliments its surroundings, and also how ergonomically
and anthropometrically efficient the design of it was, and how I could
incorporate these aspects into my own design.
Research into existing designs, and through analysing numerous
different designs which have been professionally under gone testing
and manufacturing, whether that be on a mass production or one off
production for testing stages. Through analysing the existing designs
that I have accumulated through the internet and other means of
resource I have established extra design ideas and how the
composition of materials compliment one another and aid it towards
its contemporary and Alessi based design.
Through this particular area of research I have developed a greater
understanding of the Alessi themes and history of which they have
remained to design all of their products around. This maybe either
through ergonomics through to the colour choices and finishes
applied.
Through this area of research I have developed and gained further
requirements of the different aspects of my lamp through introducing a
public questionnaire, broadening my research of which I have to design
my product around. I also have developed my information from the
questionnaire into a visual manner which can be understood more
easily. This was achieved through the use of Microsoft Excel. This
consisted of different charts showing the chosen requirements of the
interviewees.
Again through this area of research it has developed my
understanding of the different materials which could be used within
my design and how each one of their strengths and appearances can
compliment the products overall finish. The information regarding
their unique properties and how they are manufactured have been
recorded into a table so I can easily compare strengths and
weaknesses between each material.
Through all of my research accumulated I feel that it
will aid in making my product a more professionalised
and more appealing product to the customers.
Whether it be through the manufacturing,
ergonomics, or use of materials.

23. Client Requirements:
- Must be completed by May 2012
- Must be an appropriate size to effectively fit in with
an office based desk.
- Must be multifunctional
Design:
- Must relate and be designed around the Alessi based
theme
- Must be contemporary and have modernistic features
- Must consist of contemporary colour scheme, yet
withhold the Alessi design
Construction/ Manuafacture & Materials:
- The product will consist of mainly MDF, mahogany
veneer, and acrylic
- Main cuboid shape will be constructed of MDF with
either a comb joint or finger joint
- Must be constructed of materials which have
minimal impact on the environment
- Must be manufactured without exceeding £5 from
the set purchase price
- Manufacturing will consist of CAD CAM, which will
provide me with a more professionalised finish
Aesthetics:
- Must compliment modernistic style environment
- Quality of manufacturing must be to a
professionalised, industry standard
- Must look simple yet undeveloped
Anthropometrics:
- Must be ergonomically efficient for the client to
use
- Must not have any health and safety concerns
- Must be to a suitable size for a working
environment
Additional Features/ Information about the
product and materials:
- For the lighting I will be using a pre bought bulb
with a diameter of approximately 68mm, so
therefore I will have to construct a holder for the
bulb which measures 70mm housing the bulb
sufficiently causing no damage.
- Holes will have to be carefully designated through
the main body to allow the lead to follow back to
the mains source.
- Maximum size of my lamp will be 35cm in height,
and 25cm in width, to allow significant work space
on the required desk area.

25. The first of my designs as you can see has
incorporated the jukebox design, with some
slight alterations needed for the product to
be suitable to act as a multifunctional lamp.
The base of the design would be constructed
from MDF, which will be a suitable material
to use as this can be easily cut to the desired
shape on the laser cutter. The best form of
joining would be to either use numerous
dowel joints or comb joints, both of which
provide extra sturdiness to the product
when compared to other joining techniques.
The top of the jukebox can be constructed from
flexible plywood, which can easily be attached to
the MDF pieces acting as the base. This can be
done through using tacks and PVA glue to secure
the plywood in place reassuring the plywood will
not change shape.
The part of the design where the record is
normally visible and played will only consist of
maybe a vinyl sticker, which could be stuck onto a
thin piece of acrylic.
The space provided in the front of the design will
act as some sort of storage accommodation for
possessions such as C.D’s, or small electrical
appliances .
Possibly on both sides of the jukebox design
Slots where sound is normally generated through
Could act as C.D holders, and also be accompanied by
An extra storage device which the colours can be
customized and changed.
The cylinder tubing located on the front edges of the
design are there primarily to act as extra interchangeable
accessories but could also be regarded to uphold safety
issues by not exposing any sharp edges of MDF that could
be harmful to the customers. These cylinder tubes can be
made from translucent acrylic.
The bottom of the jukebox will consist of grating which
will be in front of a polymer acting as a diffusor of light. The bulb
and electrical wiring will be housed securely inside the base of the
jukebox, with the bulb positioned to be directing light through the
grating of the face of the design.
The polymer will be most
Successful if it was made from
Polypropylene, which could also
Interchangeable to set different
Moods within the specific work
Place.
Possible finishes to the design would consist of either varnishing the MDF, or to achieve a more
professionalised appearance to apply a veneer onto the MDF.

26. This design has adapted to a more Alessi based design to which as you
can see could be made from a wide range of materials, however due to
the sturdiness and strength needed from the base, it would be a good
idea to use MDF.
I think that this idea has a very simplistic design, yet has multi
functioning aspects of which will entice the customer to purchase the
product.
openings for which light is emitted from
The top of the lamp will be constructed from thin
piece of plastic, which could possibly be made from
polypropylene which underneath will consist of
numerous mirrors deflecting light into other areas
of the designated choice.
Another good aspect of this design is that it
consists of a storage device located on the front
side of the lamp, which could be made from
acrylic, however by choosing this
material it would leave the electrical wiring
displayed inside the base of the lamp, which would
not appeal to the customers.
With the base covering a large surface area the
product overall will be much more sturdy than if I
were to use a base proportional to the body of the
product.
Another good aesthetical feature of this particular design is that magnets could be placed inside the base of the lamp,
so paper clips could be placed upon. This would require testing as the magnets could conflict with electrical appliances
and battery effecting the functioning of the lamp.
This design idea has adapted again a multi functional purpose, however this design includes an i-Pod docking
station along with the necessary storage devices.
The overall structure of the lamp will be made from MDF, using comb joints to provide extra support and to
allow veneer finishes to be easily applied. This design can be made from two manufacturing techniques, the
laser cutter for the two sides and back panel, and then the Boxford router to achieve the desired front shape.
The bulb will be housed along with other electrical appliances inside the main body of the design. The bulb
will be directing light up through the centre where a mirror situated at a 45 degree angle will deflect the light
out of the square hole situated in the middle of the front panel of MDF.
Either side of the dock, will be moderate size speakers, which will be kept in place by a synthetic rubber, to
achieve a sense of professionalism and contemporary design.
Above the light admittance there are two storage compartments
that pull out for easy use and will consist of ergonomically
designed grooves so thee customer can open the compartment
easily and sufficiently.

27. This design as you can see has adapted to what seems an architectural based
theme of which Alessi doesn’t tend to base ideas and products around.
These extra shelving units can all be made from acrylic
providing an extra style of material to accompany the MDF
base.
The base again will be more successful in terms
of durability to use MDF, or maybe even chip
board with a laminate finish.
This design consists of a much more storage based product which is then secondary
function to provide light to a work space. The four draws shown on the design could
possibly be constructed from acrylic which can be cut out on the laser cutter and then
assembled easily, providing a smooth finish and a mix of materials accumulated into one
design.
This design in my
opinion can easily be
manufactured due to
the available
manufacturing
technologies and can
be easily developed
into an Alessi based
design. Hole for light to pass through and maybe
to add a polymer sheet diffuser.
All of the electrical components will be housed inside the
main body of the lamp, providing maximum security. The
edges of the base could provide an occurring safety issue and
maybe developed so that the edges are curved or have a thin
line of rubber that will connect the different panels of wood
and also provide the product from sliding around the surface
on which its placed.
This contemporary design is one of my most simplistic design ideas consisting of minimal multifunctional
properties. However, this is why this lamp design is one of my favourite ideas.
As you can see the product imitates the work of previously existing Alessi products, which in my opinion
could be developed and a range of other multifunctional purposes could be put forward into adding upon
the existing base of the design.
The lamp would be made from a fibre reinforced wood, such as MDF due to the materials durability and
strength advantages, over other similar woods.
The front of the product will be an aesthetically and ergonomically designed C.D
rack of which will sufficiently hold a number of C.D’s o the customers
requirement.
Above this will be where the bulb is situated and directing light downwards onto
a work surface and on parts of the C.D rack. Further development can be required
into a wider range of materials of which the main body could be constructed from

28. This design again I think is simplistic, yet
innovative. This design is made up of numerous
multifunctional factors taking away the aspect
of the product initially acting as a lamp.
The design consist of small shelving,
which could primarily used for stacking
paper or other small objects. These
shelves can be made from frosted
acrylic providing customization features
capable.
This design in my opinion has adapted to a
more contemporary and modern design
compared to other design ideas created.
The top of the lamp will be constructed from
MDF along with the main body. This ill then be
accompanied underneath by numerous mirrors
to deflect light out at all angles, maximizing
light sufficiently.
Another side of the lamp will be primarily
consisted of a traditional faced clock, which the
mechanisms are easily feasible. However a
more modernised clock face could be used,
such as an analogue/L.E.D.
The roman numerals placed on the face of the lamp will be made from either high impact
polystyrene or polyvinyl chloride, which are both suitable plastics of which can be used. These
plastic numbers can then be attached to a small magnet, which will attract through the MDF to
the other magnets placed inside. Relevant testing will be required to test the strong magnetism
through numerous materials which I am considering using for the main body of the lamp.
Finishes such as mahogany veneer will be a great
finishing effect and will aid to the contemporary
and modern design.
This is my last design idea and again this idea has adapted to an architectural manner in terms of the overall
structure and complexity of all the different components within the body's main design.
This design again heavily focuses on the aspect of having an alternative purpose other than just for lighting
means.
Several different materials could be considered to use for this particular design, such as; MDF and
translucent acrylic, however in this moment in time I feel that the most suitable material would be to use
translucent acrylic as I have never seen such a complex design constructed from this material. Using this
material will also give the lamp a more mood based feeling and interchangeable aspects.
The base of the lamp could alternatively be made from a much different material
like hardboard which will provide a much more glossy finish when laminated and
has numerous durability and scratch resistant properties.
Again the top of the lamp will be the direction of emitted light and reflected by the
use of numerous mirrors covered by some sort of PLASTIC: HDPE or PVC.
By using translucent acrylic the light deflecting and diffracting through the material will
create an interesting ambience and abstract aesthetical quality.

29. Here I have asked 9 people to rank these initial designs in order of which they think is best, 9 being the
highest number being better. This will enable me to specify which designs customers would like to see most
on the market and possibly for their designs. From this ranking system I will the choose out of the top three
voted designs.
Designs
Rankings
Average Rank
7
6
5
7
6
7
5
7
7
6
2
1
3
4
2
3
2
4
1
7
6
7
8
6
6
4
6
6
3
4
5
4
4
5
5
4
3
7
6
7
6
5
5
4
5
5
2
2
3
4
1
2
1
2
1
4
3
2
3
3
2
4
3
3
73 5 26 1 4

30. The systematic quantitative representation of the human body. Anthropometric techniques are used to measure the absolute and relative variability in
size and shape of the human body. Anthropometry is a key aspect of which my product could be critically evaluated in order to ensure the users
interaction with the product much more versatile. The ergonomic factors are then to ensure that product best accommodates human performance,
which overall aims to improve practicality, efficiency and also safety within a product.
This part of the lamp is the main source of
power to the bulb, which enables the
functionality of the bulb to occur. This
therefore means that anthropometrics and
the design have to be manipulated in order
for the plug to attach to the mains socket.
The shape of the design will then have to
ergonomically designed to allow comfort of
the manoeuvrability of the product by the
user.
This next photograph is an image of the bulb of
which has been pre- bought by the college. As
you can see the bulb has been designed well in
order for the product to allow a sufficient
amount of light through whilst still encasing the
bulb ensuring a high amount of security. This
casing allows the user to handle the bulb even
whilst still turned on in order to prevent any
burns due to the heat generated. As you can
see also from the design it has small air holes in
order to let some heat escape in order to
essentially prevent the plastic or in this case
aluminium from melting.
This next image is of the external switch. This
switch has been designed to ensure practicality
is much easier when turning the bulb on and
off, and it achieves this by its curvature. This
curved appearance allows the users fingers to
be easily situated inside and allowing the click
to be much more comfortable. This then is
encased inside a larger cover of which fits in
the users hands easily and consists of grooves
added for extra grip.
This part of the lamp will be engineered to allow
electricity flow through to the bulb from the
national grid and therefore will have to be
constructed from materials that conduct
electricity well. This as you can see consists of a
rubber based grip, which could be made from LSR,
which provides good grip when handled in order
for the user to plug in and out easier.
This design has also incorporated the ergonomic
factors of which are explained above by using an
ergonomically tested finger grip in order for the
user to grip the product easier. This is an
essential piece as this component for the overall
product consist of small parts of which could be
broken if not handled with care.
Anthropometry should be carefully interpreted throughout my
design where necessary to allow the interaction with the user that
whole lot easier. This could be to peruse the addition of extra grips
to the sides of my product ensuring that it can be handled with
care and moved easily if desiring to. Further testing would
therefore be needed however it would give my product that little
more satisfaction from the user giving the product an edge over
similar products on the market.

31. When a product is manufactured, inevitably there is some waste. This is
usually in the form of excess material. Good design and planning should
lead to this waste being kept to the absolute minimum. Requirements
and regulations needed to be carefully reviewed in order for the excess
waste to be minimalized and if there be excess waste be sure that the
material is recyclable. This may include reviewing the manufacturing
stages and planning stages of the product which play a vital role in
reducing the overall cost of the process and product too.
Another factor of which to consider is to explore the fact of when coming
to the end of the products useful life it can easily be re-useable in
another form and being most importantly recyclable. This evident
throughout my project and final proposed product as it has been
constantly referred to as being made from MDF which is a wood base
composite, which in itself is recycled fibres and adhesive. The acrylic also
used within my product is also another prime example of wise material
choice in terms of sustainability and eco friendly products. Acrylic being
100% recyclable.
With contingent designs towards the sustainability and environmental
factors, as well as using eco-friendlier products (such as FSC sourced
woods & 100% recyclable materials ) will provide that extra worthwhile
commodity giving the product that physical edge over other similar
products within the same market range. Also with my specific design
being able to house the bulb as well as easily being able to remove the
bulb when coming to the end of its useful life again saving money
purchasing a completely new product as many users do. Another
important factor of which to focus on would be that my lamp will be
mains operated which is still isn't environmentally friendly however is
compared to that id the lamp was powered by batteries which would
constantly have to be replaced requiring more energy in order to produce
more unnecessary products.
This is the world wide recognised
logo of Forest Stewardship Council
that provide an environmentally
friendly source for harvested
woods, as they replant what is
felled in a controlled environment.
Another important stage of which I mainly focused my steps to a more
eco- friendly approach to designing and production would be during my
modelling stages of relevant materials in order for me to gain a more
ensuring aesthetic feel towards the chosen product. It also provided me
with an insight to the possible faults of which could occur when the final
stages of production are imminent. The modelling stages were therefore
constructed from recycled materials, such as; MDF, and other various
forms of offcut material which will be recycled once accumulating my final
product.
Another factor of which I tend to abide by when proposing the
manufacturing is the 6 R’s being:
- Recycle
- Re-use
- Rethink
- Reduce
- Repair
- Refuse

32. Here as you can see, I have developed my initial design ideas
through using Google Sketch up and have rendered them in a
specific way into which I will develop at a later stage. This will allow
me to gain a greater understanding of how the products look in a
360 degree perspective and the feasibility of the idea also.
The first developing idea I have chosen to work with is my first
initial idea of a jukebox. I have developed decorative additions to
the exterior of the base, which includes frosted acrylic, which will
be either bent or numerous tubes will be cut and shaped to
achieve the curved shape.
I have also decided to develop the grating of which the light from
the lamp housed inside will be emitting light through. If deciding
to use a grated surface which was composed of large holes, then
I could also possibly consider a polymer diffuser, to reduce light
intensity. This diffuser could possibly be made from
polypropylene or frosted acrylic.
I decided to create a simplistic base model
of which the design would look like and then
added upon such as the other decorative
finished initial ideas.
With the overall base of the jukebox being
made from MDF the components required
will be easy to produce for this particular
one off production and also that of a large
scale in industry.
This here is a close up of the storage compartment where
stationary of other items of an office desk can be stored.
Made from acrylic, preferably a colour complimenting the
wooden finish of a jukebox will allow less friction to occur
when opening the draw than to that if the draw was made
from MDF also.
The cylinder shapes located at the bottom of the lamp
design will be made from two circle pieces of MDF with a
quarter of the pieces missing allowing it to fit to the base of
the jukebox. The remaining cylinder (the curved wall) will be
made from flexible plywood which will be glued and tacked
into shape to maximise sturdiness and durability.
Another possible feature I'm deciding
whether to use within this design is the
particular finish of which will be added to
the jukebox. This will consist of either a
varnish added upon the MDF and plywood,
or to cover the entire product with a
mahogany veneer, both giving the same
quality finish

33. This is the first development stages of this multi functional lamp, which provides more
contemporary and satisfactory feel towards the product whilst still maintaining the Alessi based
theme due to its quirkiness.
This particular product could be manufacture from three separate components which could the
later be fitted together. These components consist of; the base made from preferably a
hardwood giving a positive aesthetical and professionalised feel, The base of the lamp which
could be made from MDF and the draws made from a thermoplastic, and also the last
component the shelving on top of the primary base capable of holding C.D’s and other office
equipment.
This is an image of the base of the product housing
the bulb and containing numerous storage devices.
The emitting light from the bulb housed within the
base is directed outwards parallel to the work
surface and therefore needs to be directed
downwards by this mirror attached to a piece of
MDF. The draw also visible in the image will be made
from MDF with an ergonomically designed
thermoplastic handle such as ABS or acrylic.
This image focuses on the idea of collaborating the idea of
a docking station and large speakers embedded within
the base. The docking station’s electrical components will
have to be purchased outside of college and disassembled
and relocated into different areas required.
The two storage devices could be made from HIPS as this
material provides a range of colours adding the ability of
customization for the user, and can be easily
manufactured through vacuum forming.
This is the shelving component located at the top of the
product allowing space for desk equipment to ne stored,
such as paper, books, and other important documents.
This is primarily made from MDF for the actual shelving
and frosted acrylic tubing for the stands of which will
contain slots where the shelves can be slotted into place.
As this component will be made separately slots will be
needed on the base of the lamp so that the acrylic tubing
will fit comfortably into place.

34. This is a development of which I think is the best design of
my initial ideas as it’s the quirkiest design and is a
collaboration of the most unique multifunctional devices.
These multifunctional devices consist of; a stationary holder,
light remittance, grooves for holding C.D’s, and possibly a
docking station.
The overall body of the lamp will be constructed from MDF
designed on 2D design and then cut out on the laser cutter
producing a high quality finish. All additional panels will then
be comb jointed on to provide additional sturdiness and
strength to the body of the lamp. This then could be capable
of being covered with a veneer of some sort.
This is an idea of incorporating a docking station
within the product located at the back of the
product and additional space will be needed for the
speakers electrical components. However from
designing and developing the idea of a docking
station will not be feasible as the product will cost
too much to manufacture and will consist of
unwanted electrical faults.
This is an image of where the bulb will be housed in
the product. The bulb will need a slim fit bulb holder
allowing minimal space for manoeuvrability of the
bulb. This particular component will be made out of
MDF and comb jointed together.
This is a close up of the stationary
accommodation located directly underneath
where the lamp will be directing light onto
the surface so user can clearly see what
equipment is placed within this area.
The image below is a close up of the last
component of the C.D rack. This I think is a
unique design compared to other similar
shelving for C.D cases and this will be a good
aspect of which customers will look for in
products.

35. Here are images of a card models I have made roughly to a scale
of 1:3 as it was the most feasible design to make from card. All
the nets of the cube shapes was firstly drawn and cut out
separately then assembles ready to all stick together, rather than
making one large sophisticated net of the product. This then
provided me with further knowledge of the different components
needed to make the product and the possible material choices of
which the product could be made from.
From the card model I realised the difficulty into making this
particular design, especially the grated front panel of the product
enabling a controlled amount of light being able to emit through
and also the curvature of the top of the product which is the key
design of the jukebox. Another reason why I don’t think this
product will be successful is that there will be difficulty attaching
additional features, such as; the storage devices and possibly the
docking station which will be added at the bottom of the design.

36. This is a card model of again roughly to a scale of
1:3 of my preferred design of myself and also the
client being Mamby’s D.I.Y establishment.
The idea of producing a card model such as tis is
for me to gain some understanding how all the
component could possibly fit together and also
how the product may appear to look in an office
desk environment. This will then dictate any
further adjustments to the size and shape of the
lamp to be suitable for that particular
environment.
With using a basic card model of a third of the
actual scale may not be exact in telling me what
the exact sizes will be, however it will provide
me with a rough estimate of the dimensions
required in order to house the bulb sufficiently
and so on. Another reason of producing card
models is to understand how feasible the
product will actually be.
Further developing and testing of this shape will
be needed to carry out and possible material
changes to the modelling. For example, MDF and
acrylic could possibly use for modelling and from
this dictate what improvements will be needed
for the product to progress and be successful.

37. This in relation to my testing pages is just a brief overlook at what the other initial ideas
I designed on previous pages would look like if produced from Transparent Acrylic,
however relevant testing such as this card model was needed in order to ensure all
components dimensions were relevant.
In order for me to gain a grasp of the correct dimensions I firstly, as you can
see have made a similar scale model however made from Grey Card,
reducing waste material when coming to laser cut the Acrylic components.
The cube shape as you can see form the majority of initial designs is what
they are all based around with minor additional features of which I could
consider adding if content with the finished Acrylic model. With the idea of
the cube is so that this particular shape is easily adapted into any form of
additional features and components of which will allow the product to
progress in different directions.
As you can see The model was constructed from the Grey Card displayed in
the photographs below using a 2D-Design template of which I will also use
for the other Acrylic model and cut out on the laser cutter, producing a high
quality finish and a time effective alternative when compared to cutting
out the comb jointed panels by hand using a craft knife.

38. This then as you can see is the Transparent Acrylic model, which provides an
excellent encased light source housing the bulb inside. This is due to the
initial emitted light from the bulb the reflective properties of the Acrylic
casting light out in numerous directions allowing maximum light to be
produced to the desired work environment.
I also really like how the comb joints are highlighted by the bulb being
encased so compact, this therefore could be the bulb case and consist of an
outer shell of additional storage components and stationary holders
consisting again of a transparent finish not effecting the light emitted.
With this cube acting essentially as the bulb compartment, with a distinct
colour projected as you can see could easily come in a variety of colours
enabling the lamp to be adapted to any gender or age range, or any styled
environment of which it would be situated.
If pursuing this idea of encasing the bulb in this Acrylic cube I would have to
allow the lid to be removed on order to change the bulb safely, increasing the
products overall useful life, or simply add a hinge or catch of some sort to slide
and remove the lid easily.

39. With the recent development of ideas I realised it would be a
good idea to return back to my client (Manby’s D.I.Y store) and
inquire as to whether the establishment would like to pursue
the developing idea of the jukebox before further
development can be added.
When confronting the client they stated that the idea of the
jukebox was too much like a novelty idea rather than relating
to the Alessi based theme, and consisted of too much detail
and could possibly cost the establishment much more to
manufacture, reducing the overall profits and sales of the
product, if compared to a much more feasible design.
The reason why I chose to confront the client at this particular moment was to see whether the product will be
suitable for the current market of which the establishment is focusing on and analysing the feedback from the
interviewees from both market research and my rankings page both agree on the quirkiness of the below product
being much more contemporary and Alessi based and a product they would be happy to purchase themselves.
Contingent to my initial thoughts and design ideas further
developments will be made to the S idea situated bottom left and these
will include developments to the aesthetics and functionality of the
product. The product such as the Jukebox interviewees described the
idea as being too ostentatious and much ore like a novelty product than
an Alessi based idea, which has enabled me to focus solely and peruse
the functionality and aspects of this design.

40. These are drawings taken from my developing idea of the “S”
design as you can see from the image to the right. These
drawings of development are progressive ideas of original ideas
for my product and you can depict from the images the range of
multi functionality the product can provide to the user.
This is the first function of my idea, which is the most noticeable at first
glance than any other function which is a unique setting the mood of the
Alessi based theme. The spacing's between each new shelf will have to
be designed around the average thickness of C.D case enabling all types
of cases to be stored within the spaces. This will also be aided due to the
fact of the unique angle of which the grooves will be allowing the cases
to rest. Such a unique design such as this one will need to be
manufactured by hand through the use of circular saw which can easily
be manoeuvred at the desired angle to achieve the intricate angle. The
material which will be most suitable for the production of this
component will be MDF with a thickness of around 45-50mm. Another
additional feature of which I have considered would be to add thin strips
of veneer to the grooves so the whole product has a consistent look.
This is a brief look at how the main function of the product being a
lamp is to produce enough lighting to the surrounding area of the
working environment, being an office type desk. This design will
contain a slot for the bulb to sit inside with a smaller circle curt out to
allow the bulb to rest on and hide the thermoplastic rim of the bulb.
This will be deigned on Pro Desktop and then fed through to the
Boxford router where complex 3-D shapes can be produced. The
material that would be most suitable would be again MDF to allow the
product to have a consistent material used for production and the
easiest material to work with an cheapest.
This development of function is the storage
of C.D’s on the front of the product which has
been rotated vertically to allow a different
perspective of how the product could look
this way. This design will be much easier to
make than the first initial idea however I
really like the unique properties of the other
design and intend to pursue that idea further.
Again this design will be produced from MDF
and if deciding to use this design the veneer
that I will be adding will be much easier to fit
onto.

41. This is the first of my testing for the development of my S design
lamp of which it consists of shelving, designed to withhold C.D
cases at a 135 degree angle for easy withdrawal for the users.
With the testing piece of wood made from Walnut I don’t think
that this material would be feasible as the cost compared to MDF
of which the product could be made from raises questions about
the cost to manufacture the product on a large scale.
The particular grooves as you can see from the image bottom left
the grooves cut out was done on the circular saw with a
manoeuvrable blade for the intricate angles desired. Another
factor of which to consider is that I wouldn’t be able to make all
of my product out of the material and therefore would look
unprofessional and the cost to manufacture would be too much
reducing profits from sales.

42. By testing the hardwood C.D rack made from Walnut, I knew that another
alternative would have to be in place in order for the idea to function
properly, and to also be feasible in terms of matching the rest of the design
that would be made from MDF, and also reducing the cost, using a cheaper
material alternative.
I designed the C.D case on the Boxford Routers own design programme,
called Boxford Router Design Tools. The photographs taken of this
production consist of the design on the computer, the MDF panel routed to
the desired shape, and testing the C.D rack.
Testing the C.D rack before gluing this component to the existing body
structure also made from MDF proved vital, as I soon found out that the
design was not successful, as the panel needed to be much thicker in order
for me to route in further, providing additional surface area of which the
C.D cases would have been encased in. The average size of the C.D case is
around 11mm and therefore I felt that it would benefit from a width of
12mm, however its because of this additional space It causes the cases to
tilt and possibly not being able to use if the C.D cases are much thinner.

43. Another possible aesthetical feature which
could be added to the product is a docking
station with two individual speakers, however
with this feature being added there will be
possible electrical faults. As this will be located
at the bottom back of the product all the
electrical appliances will be stored within the
product which further measurements will be
needed to allow a comfortable fit within the
hollow casing of the MDF.
This is another quirky aesthetical feature
which will interest the market and stand
out with its unique routed design on the
panel of MDF. However recent
development suggest that this idea will
not be feasible as the different panels of
MDF will be comb jointed and therefore
parts of the MDF will have to be hand cut
rather than all be routed. Or possibly with
correct measurements could be cut out
on the laser cutter, providing a more
precise finish.
With the problems concerning the stationary holder
and initial routing idea, I then started pursuing a
different approach by incorporating an extra piece of
frosted acrylic or H.I.PS to be slotted into the top
panel of the MDF visible within the diagram above.
The material will be heated on the strip heater and
then bent around a 90 degree angle to provide a
good quality finish whilst still malleable.
There would be two stationary holders produced for
both sides of the product and the shapes measured
around the average size of equipment and cut out on
the laser cutter.

44. This in my opinion is the most vital factor to consider when
moving from the design stages to a manufacturing stage
and therefore clear diagrams of how the bulb will be
housed in the product and maintained firmly in place. The
sizes as shown above will allow all of the light emitted from
the bulb to be visible being a radius of 66mm and the outer
radius of the holder to be 70mm, leaving a mm in radius of
space for the bulb to be placed in.
Here is a design of the bulb holder of which the bulb will be
comfortably situated in and providing minimal space for the bulb to
move around, holding it securely in place.
This design could be designed on Pro Desktop and then once satisfied
with the certain dimensions could then be cut out on the Boxford
Router. The material of which I explained in previous pages will be MDF
so it will be easy to work with such a complicated design.
This is an overall view of what
the wiring and bulb will
roughly look like when
secured inside the product.
The only problems of which
may occur when designing this
particular design is the wiring
leading from the bulb to the
ergonomically designed
switch.
As shown from the two drawings on the right I allowed space for the
wiring to be fed through with minimal space around the wire to allow
dust to accumulate inside. The measurements for the hole will be
around 4mm x 4mm situated in the corner edge of the two meeting
edges of wood.
This is an additional feature of which will be channelling the light
from the bulb outward rather than the majority of light being
shone upon the product itself.
To achieve this an additional piece of MDF could be attached
behind the emitting light and directed outward to the
surrounding environment Then a carefully cut mirror would then
be glued on. Or the whole additional piece could be constructed
from a thermoplastic, such as; acrylic or ABS, which can easily be
vacuumed formed.

45. Here is a two-point perspective depiction of what my finalised product will look like. I decided that this drawing technique was best
to use as it clearly shows all components of which I will be collaborating within my design. The main components of which I will talk
about are as follows; main body structure, C.D rack, stationary holder, and the housing of the bulb.
The C.D rack as displayed below will be situated
on the front bottom panel of which will be
made from white acrylic components ensuring
that it provides a comfortable fit for the average
sized C.D case. The sizes will measure by
139mmx139mm, which will be encased inside
the MDF panels accordingly.
The last component of which is displayed within
my drawing is the stationary holder of which
needs to undergo extensive testing and
development in order to reduce the amount of
material used. The most suitable choice of
material to use would be acrylic as this material
is also easy to work with and is 100% recyclable.
The holders will be designed so that there is
enough space to place pens/ pencils allowing
little room to move ensuring that the stationary
does not fall out.
The body structure for the lamp will
be made from comb jointed pieces of
MDF as its extremely easy to work
with and is a suitable base material for
a hardwood veneer to be added upon.
Other positives for using MDF are due
to that the material is eco-friendly and
is sturdy enough to withstand extra
additional weight. All MDF panels will
be covered in a hardwood mahogany
veneer for an extra aesthetically
pleasing appeal.
The first component of the lamp will
be the housing of the bulb of which as
you can see is situated above
stationary holder which emits the
sufficient amount of light. The bulb
will be housed within the hollow base
of the upper body, which will securely
rest upon a cut circle consisting of a
38mm radius.

46. Here are two examples of an exploded drawing. The drawing to the left is of
my main body structure which will be constructed from MDF, and to the
right is the Acrylic C.D rack. These drawings were designed to enable me to
achieve a greater concept of what the product I have briefly designed on
paper will look like when assembled when constructed from a material, such
as; MDF or acrylic. This will also maintain the recent adaptations to the
sustainability factors I have mentioned and to ensure that my product and all
models are eco friendly, producing less waste material. The exploded
drawings of these two components were constructed using the software
2D- Design.

47. Key:
1. Made from Acrylic
2. Made from MDF
1
1
1
1
2 2

48. Other than previous card models of my developed
chosen design, this is the first card model of the
final design. The material most suitable in my
opinion to model the idea was to use Grey Card,
as this material is more economically friendly
when compared to that of Acrylic or Medium
Density Fibreboard, and also is easy to work with
which also saves time and produces less waste
material.
The reason for this first model was too simply
grasp a greater concept of the actual finalised
dimensions of the product enabling a more
precise cutting template to reduce the amount of
waste produce when coming to making it out of
the best chosen material.
The model was roughly scaled at the same
dimensions to that of the actual; orthographic
drawing which I had produced at an earlier stage
in the project. Because of the similar dimensions
of which I think the final product would consist of
this provided me with an easier starting point of
which I could then build on to start designing the
different components and to plan carefully the
comb jointed MDF panels of which would
mineralise or even remove any design
miscalculations.

49. Here I have made a rough full scale model of my proposed design
idea and rather than make out of card again produce it in a different
material, being MDF to see what other possible materials would be
suitable into the production of the product, MDF being the initial
and most suitable material choice. Another reason of which I
produced this MDF model is to ensure that the chosen fixatives and
joints are suitable and are most effective within the product, which
will produce the overall base of the design and how it will withstand
in an everyday working environment.
With the exact same process of producing the acrylic model by using
the laser cutter with 2D-Design templates, which as you can see
provides the exact same shape and design however produces an
entirely different aesthetical appearance towards two complete
different audiences. A pre-existing problem with producing the
product out of MDF is the black burnt edges of the MDF where it has
been cut out on the laser cutter, and if deciding to remove them will
require additional time to sand them down. This then provides an
even bigger incentive to the apply the additional mahogany veneer.
As you can see also the routed design for the
C.D holder has been tested in the vice and has
worked sufficiently securing the C.D case
comfortably with approximately 2mm between
each strand of MDF.
With a greater insight to how both Acrylic and
MDF perform in acting as a body for the
product I believe the MDF and acrylic materials
can both be incorporated within the final
design complimenting one another with the
MDF also being encased by the desired veneer.

50. When again approaching the client with new developed design
idea, with all the additional new features and multifunctional
aspects of which I have incorporated into the developed idea, the
client highlighted that the product seemed to bland. This
therefore needed to be addressed and when presented with
photographic images the focus point for further development. As
you can see from the images above the C.D rack consisted of a
very simplistic design in terms of appearance and functionality.
The client highlighted from the design specification that the
product needs to be modernistic and consist of contemporary
features. The client specifically stated with the use of all wood
that the product needed a collaboration of materials rather than
just one complete product consisting of the same material
throughout.
With receiving recent feedback from the client I then started to construct the C.D rack from a more contemporary looking material of which would not
need to apply a finish on and from this guideline I decided that Acrylic would be the most suitable choice of which to use. Constructed with similar
dimensions to that of the MDF initial C.D rack I had no trouble simply substituting the acrylic C.D rack into the pre made slot with some additional
holders which maintained the hollow structure and gave the additional surface area needed for the application of Araldite. When receiving relevant
proposals for improvement from the client I then reproached the client with the idea of using a much more sophisticated and contemporary design in
terms of the aesthetical views of the C.D rack and also explaining that this component along with any other components made from Acrylic or other
forms of plastic for that matter would save the cost of applying a finish to that material as they're already self-finishing and look aesthetically pleasing.
Other than this aspect of which has been addressed
and improved accordingly, the client had critically
analysed the product and was overall pleased with
sophisticates structure and how it had incorporated
the multifunctional features as par of the body, as the
majority of products when multifunctional that they
appear to look as not part of the actual design and
just an additional feature whereas this doesn’t and
works really well within the design specification.

51. Start
Set up laser cutter
Quality
Control
Cut out desired MDF
panels (Refer to 2D-
Design
Assemble together
using cut out comb
joints
Fix MDF body of lamp
together with PVA glue
Cut out desired C.D
Rack using 2D-Design
template
Glue pieces of C.D Rack
together using Tensol
Pass
Fail
Fit it to the opening
in MDF base of lamp
Quality
Control
Fail
Apply spirits to
remove burn marks
on the acrylic
Cut out the 2D-
Design template of
stationary holder on
laser cutter
Assemble and glue
using Tensol
Attach to body of
lamp using Araldite
Quality
Control
Pass
Pass
Fail
Laser cut
150x150mm pieces
of acrylic and attach
handle
Place lid with comb
joints interlocking
with corresponding
MDF joints
Quality
Control
Cut out 2D-Design
template of veneer
Fix down onto
exterior sides of
MDF using PVA
Attach bulb in place
at top of the lamp,
fix bulb holder
additional piece of
MDF to bulb to fit in
with PVA
Finish
Fail
Pass
Additional Notes:
- Ensure when using the laser cutter when
using different materials that the settings are
changed accordingly.
- Ensure all quality control steps are carried
out under the necessary supervision whether
it may independently or with teachers
assistance.
- When using any forms of strong adhesives
that you take care as some are relatively
harmful.
30 mins
60 mins
30 mins
15 mins
60 mins
QC.1
QC.2
QC.3
QC.4

52. Quality Control checks are techniques are used in all areas of manufacturing. It is a technique used to check quality against a set standard or specification. It may be used to check the
dimensions of a product or component. When compared to the required specification set by my client I will be confirming the relevant dimensions when compared to the set
specifications.
My quality control checks have been set in place to acquire maximum quality in the manufacturing processes of my product and I will assess the product again once it has been finally
produced. When relating back to my production flow chart I have labelled the quality control checks accordingly and various techniques will be used to assess the quality of the finished
product.
Quality Control. 1 – The first quality control check will be carries out to
ensure the laser cut pieces of MDF are all to the required size a fit
promptly together with ease. This will be achieved by the use of a print
out before assembly of each individual panel, comparing the
dimensions.
Quality Control. 2 – The second quality control check will be to ensure all Acrylic
parts of the lamp are cleaned thoroughly using spirits and when gluing the base
model together ensure that all dimensions are geometrically correct with the use of
a tri-square. The dimensions of the product could also be measured with the use of
a ruler ensuring all measurements were required are the same.
Quality Control.3 – This controlled step is to ensure that the Acrylic
components are assembled correctly when gluing it to the main MDF
base of the lamp. This will again be assessed through the use of a jig
and possibly measuring equipment, such as a ruler.
Quality Control.4 – This quality controlled procedure is the assessment of the
measurements of the final Acrylic components of which this will be the main initial
focus point on the lamp as they stand out most on the product. This will consist of
using printed out templates and measuring equipment are to all the required length,
and to ensure maximum quality.
The final stages of my product also undergone an overall quality controlled assessment to ensure the products geometrical shape was suitable for the design specification, and to also
ensure that the veneer application is to a high standard of which is the final process in my manufacturing of the lamp. As you can see from the accumulated photographs below all the
quality controlled steps were recorded to allow me to look back if needed to distinguish certain factors if there are any faults at a later stage in the manufacturing.
MDF panelling as evidenced on the images below were also set against the templates and were
incorrect and therefore rather than cutting new pieces. I simply sanded down the original
panels saving material and producing the exact requirements.

53. Part Material Thickness Size (mm) Colour Quantity Finish
Base Lid Acrylic 3mm 150x150 White 1 None
Main Body MDF 6mm 300x150 Beige Refer to
Orthographic
drawing
Veneer Application
Stationary
Holder
Acrylic 3mm 150x100 White 1 None
C.D Rack Acrylic 3mm 139x139 White 1 None
Manufacturing Spec. Reason For Use
MDF, Various size Panels, comb jointed Provides far more strength when compared to synthetic
polymers such as Acrylic, and greater gluing surface area
Acrylic, 1 148x148mm panel, C.D Rack Aesthetically pleasing appearance, self finishing
Acrylic, 1 150x150 Lid Aesthetically pleasing appearance, self finishing
Hardwood Veneer, Various sized panels To provide the man made board with more aesthetically
pleasing quality, as MDF is very bland
Acrylic, 1 Stationary Holder Aesthetically pleasing appearance, self finishing
Bulb, 1 To provide main functionality of lamp

54. Here are some images of the computer aided
manufacturing I developed on 2D-Design which was then
was cut out of materials using the laser cutter being the
most prominent form of CAM. The various components
of which my lamp is categorised into were created on 2D-
Design and cut out with various power and speed
settings for the different material components. With no
engraving needed to be added to the base MDF model I
used on black lines indicating that simply the shapes
needed to be cut out efficiently.

55. This again is another prime example of Computer Aided
Manufacturing. However, this is focused solely upon the designing
and making of my C.D Rack and Stationary Holder of which is
displayed through the 2D-Design and to give you a greater concept
of the practicality and finished component images of the
assembled components.
Again with the same manufacturing process of using the laser
cutter, but with the speed of which the material has to be creased
when compared to MDF as it cuts through far more effectively and
this therefore in production terms means more can be massed
produced faster and sufficiently with the same high quality finish.

56. With my current proposals regarding the stationary holder to be
embedded within the product rather than an extra additional feature, has
been successful in terms of the aesthetically pleasing aspect of both wood
and Acrylic complimenting each other and portrays a contemporary feel.
Using 2D-Design and cutting the component out on the laser cutter
creating a firm stationary holder of which pens and pencils of up to 8mm
can be stored, as opposed to using MDF initially proposed to construct
this aspect of the product, however this would be less economically and
environmentally friendly, and would also boost the cost of the production
towards this product.
Below are numerous photographs taken of the 2D-Design shape, and
assembled component of which was assembled using Tensol 12 to attach
the acrylic pieces together. As you can see from the photograph situated
bottom left it comfortably encases the pencils with ease with little room
to manoeuvre and fall out of the holder.
I then decided to test the idea of the entire front of the product being
made from acrylic stationary holding equipment which enabled me to
realise that the various components interlocked which then some of the
spaces provided to hold stationary were useless, and therefore from this
testing was dismissed.