Speaker / Lamp

Speaker Lamp
Course: Design Technology 0445

Contents
 Problem and design brief
 Analysis of design brief
 Initial Specification
 Research into existing products
 Product analysis of PRIMARY research
 Materials, components and adhesives
 Materials testing
 Ergonomics and anthropometrics
 User profile
 Analysis of research
 Design specification
 Initial design x3
 Development of ideas x3
 Modelling and testing x2
 Final design
 Cutting list
 Evidencing CAD/CAM
 Plan of making x2
 Manufacturing Diary x4
 Evaluation x4

Problem and design brief
Problem
Listening to music around the house, and reading book’s in bed can sometimes be difficult, due to low light and sound quality. To solve this
problem I will design and make a multi purpose speaker-lamp, preventing these problems occurring in everyday life.
Design Brief
The speaker lamp must be small enough so it can fit on a bedside table, or a shelving system in the house, to prevent damage of falling and
breaking. The product must also be suitable for teenagers and adults and have a medium, affordable cost that competes with current
speaker-lamp systems. In addition, the speaker must link up to a phone, thus music can be played easily. Furthermore, the speaker-lamp
must have a sturdy base to hold its own weight of the lamp component. This will avert the chances of the speaker lamp falling and breaking.
The lamp part, also has to be in a position on the product where it is able to project ample light. This would be useful as it ensures efficient
use of the lamp component, in addition, enabling full use of the product and not wasting any of the money and cost. Moreover, this product
must be easy enough to mass-produce. Therefore, the product must include elements of CAD/CAM, to ensure it can be duplicated in
industry multiple times with ease. In addition soldering will take pace, in order to complete the circuit boards for the speakers.

Analysis of design brief
Who is the product aimed at?
The product will be aimed at teenagers and students, both
young and old. There is no specific age to which the product is
limited to, however, It would mostly be aimed towards students
who like to listen to music, and or read at night. The product
may also appeal to the older ages, such as students in
university or even post university students as a means of
relaxation.
What should the product do?
The product should be able to produce a high quality sound
through the speakers component. Through this, the audience
should be able to play music from their phone, and it should
enhance the sound to make it louder. In addition to supplying
amplified sound, a dim light should be supplied so you have the
ability to read beside it.
How will the product meet the demands of an environmentally
friendly environment?
To ensure that the product is suitable for the environment, I will use a
form of wood. This is environmentally friendly as wood is one of the
most sustainable materials in the environment, as it is natural, can be
re-planted to sustain volume and has the ability to decompose in the
earth at the end of it’s life cycle. In addition to this, I will use acrylic.
Acrylic will be suitable for the environment as it can be recycled and
reused, to create a new product. Moreover, I will reduce my waste.
Through the project, I will use a minimal amount of material to cut
back on both cost and waste.
What will be used in order to make the product? (materials,
tools)
The product may include elements of acrylic (for the stand),
plywood (to enhance the acoustics), and vinyl stickers (for
decoration). In addition, circuit components will need to be
used for the assembly of the speaker and the lamp
components.
How will the product be stored, and how will this effect the
overall design?
The product should be stored on a bed side table, or on a desk.
This will alter the design as the product will need to be suited to
fit into small spaces. In addition the product will need a sturdy
base to prevent collapsing, or the product falling of the table.
How will the product be assembled?
The product will have different sections to be assembled. A variety of
techniques may have to be used to assemble the products sections.
For example, bending the acrylic, using the strip heater for the shape
that is needed. In addition, I may have to use adhesives and solder to
assemble the components of the lamp and speaker, and to attach
these parts to a base, for the overall product to be complete. Different
adhesives such as araldite and PVA can be used.
How will I ensure that the product is suitable to mass produce?
To ensure that the product is easy to mass-produce in industry, my
product will be made with the use of accessible, industry linked
machinery. For example, I will use acrylic, cutting it out with the aid of
CAD and CAM such as 2D Design tools for drawing and the laser
cutter for manufacture. CAD/CAM makes it easy to mass produce,
with accuracy, duplicating the product over and over again.
Numerous features or pieces can be cut out using this process.
How will cost restrict the production of the product?
The cost of the material may effect the product. As a result, it may
limit the materials I am able to use. However, if I pick less expensive
materials and reduce the waste of the material used, by only taking
as much as my product needs in order to be efficient and effective the
cost won’t be effected heavily. If mass-produced in industry more
luxurious products could be used depending on the client.
How will the product be successful?
I will ensure success of the product by relating its purpose and
function, to aesthetically appeal to the targeted audience. In
addition, I will ensure that the ability to use the product is up to
standard, solving my initial problem.

Initial Specification
 The Target market of this product is ages 8 years and onwards. This is because there is a large percentage of people who listen to music, however if younger than
six they may not be as capable to use this technology without harming themselves and or others.
 The product will be suitable for any Religion, and will not contain any offence signs that could offend a particular facet of society. Thus making the product open to
any religious beliefs, respecting each individuals values.
 The Purpose of this product is to project a good quality sound and light, in order for the consumer to read in the dark, and listen to music anywhere, as it will be
portable.
 The Environment that the system will be in is not limited. As it is portable and due to its purpose it should be able to be place on a bedside table and or counter.
However, also needs the stability to hold its self up on the floor, or other places on the ground weather it is inside, or out.
 Due to it environment, and the conservation of the environment, the product must be limited in Size. The product must be small enough to fit on a small table, or
equivalent space on the floor.
 The Weight of the product may also be limited. This is related to the purpose and target market. Due to the fact it should be a portable speaker system with the age
limited to 8 years and above, the weight of the product must be kept small so that it is easy to carry around and move.
 The Durability of the product should be good, as the product should be expected to last around 3-4 years. The product must be durable as it may be found in spaces
where its knocked around or placed on a rough surface, thus preventing damage.
 The Aesthetics of the product should be limited to plane patterns, however bolder colours, as its suited for such a wide range of people, it needs to be appropriate for
everyone. In addition, it needs to suit any environment its in.
 The product has to be made out of Materials that have a range of functions. Such as, lightweight, waterproof, fireproof and strong.
 The Cost of the product must be relatively cheap and affordable due to the large consumer market. Therefore, the materials must additionally be cheap.
 The product must also take into account Environmental issues. For example, the materials used must have the ability to be reused and recycled to form another
product. Moreover, the waste of the materials must be minimal. Furthermore, the materials chosen must be the most sustainable materials that are available.
 The product must be suitable for Mass Production in a factory or workshop. Therefore, the product must include elements of CAD/CAM to show that its suited for this
Manufacturing process. These elements will be incorporated by using the 2D design, the laser cutter and vinyl plotter.

Research into existing products (Internet)This lamp is designed in the style
of art deco, 1920’s and 30’s. This
inspired theme gives the product
an aesthetically pleasing look. In
addition the materials used such
as metal
and a mesh material, gives the lamp texture, adding to the
overall aesthetics, and allowing the light to pass through
nicely. Moreover, the size of the lamp is small, thus fitting on
a table and other appropriate areas. This lamp may be
aimed at an older target market as the design and
aesthetics are mature. The lamp gives a versatile look for
the environment that it is designed for, due to its plain color
scheme and pattern. This lamp appears to be costly due to
its high quality materials and art deco inspired design. The
cost would have been reduced by its small size, and the fact
it can be manufactured through CAD/CAM; on a laser cutter
to cut the sheet of metal. The lamp is environmentally
friendly as the materials can be used again to form another
product at the end of its life cycle. In addition, when
manufactured the material waste can be reduced when
using CAD/CAM. Lastly, you can see that the corners of the
product are rounded to ensure the safety of the product so
the consumer is not at risk of injuring themselves on any
sharp edges.
This lamp is made out of wood, with slits allowing the light to pass
through, and rounded corners, almost in a rectangular shape.
Suggested in the style of the ‘Absolute World’ towers design.
These features make the lamp aesthetically pleasing, due to its
smooth organic appearance. In addition, the product is
sustainable, as its made out of wood, which is the most
sustainable material on the planet as it can decompose when in
landfill and be replanted many times. The product is also safe,
due to its rounded edges, making the product smooth to avoid any
accidents.
The cost of this product may be high, due to hardwood being used. Hardwood is
expensive because it takes much longer to grow and therefore has a more damaging
effect on the environment. This would have a wide target due to it’s interesting design. It
would be suitable for 8+ as it is fun, quirky and mature; attracting all age groups. The
product may be hard to produce in mass due to the intricate detail; thus making it more
costly to purchase.
This speaker docking system is made from wood. The wood appears
to be smooth and shiny due to the process that the wood has gone
through, and the use of a clear wood varnish, thus making the
product darker too. This makes the wood look tidy and aesthetically
pleasing, enhancing the maturity of the products consumer. In
addition, the product contains two speaker components. This also
adds to the effects of the
This product is aesthetically pleasing for an older consumer
market due to its retro style. The products attributes give an
overall aesthetically pleasing look if you are into this
particular style. The product itself is small. This is good as it
has the ability to be place practically anywhere in a room,
however wouldn't suit all décor, thus limiting the consumer
market. Furthermore, this is not environmentally friendly as
we can infer it’s made from some type of leathery, thick
material. This has a negative impact on the environment as, to
burn it or try recycle it, it would accumulate a lot of harmful
fumes and toxins into the atmosphere. However, some parts
on the product may be able to be reused to create other
products. Moreover, the product is safe for the consumer, due
to its smooth surface and rounded corners, however alike to all
the other product can be harmful due to the electrical
components used. Furthermore, the cost of the product may be
high due to the use of these materials. Lastly, this product
would be hard to manufacture in mass, as a lot of the details
have been hand crafted and produced.
aesthetics, in addition, making the product more costly but effective when in use. The price
of this product will be relatively high due to the materials and components needed.
However, the use of wood means that the product is very sustainable and can be reused
and recycled. Moreover, the products target consumer will be wide as the aesthetic can
appeal to many, due to its simple and tidy appearance. In addition to this, the product
appears safe, as we can see all the corners are rounded off. This will prevent harm to the
consumer in an accident. The product however appears to be heavy. This limits its ability
to be portable. In contract, the product is relatively small, reducing the material needed
(reducing cost and environmental impact), and giving it the possibility to be placed on a
small table.

Research into existing products (Catalogues)
The lamp shades simplicity makes this
design stand out for me. The aesthetics are
based around the simple, white paper/
fabric used. I like this because its makes
the lamp appear sold and homely. The
product could be used in any environment
due to its plain, solid colours and very
simple design. The lamp would be cheap
due to its material, as it has been made
using recycled card / fiber. The product
would be environmentally friendly due to
the material used, as at the end of its life
cycle it can be reused to make another
product. The lamp would be easy to
produce in mass due to its simple origami
structure and design.
This product may be designed in the style of a building, due to its
tall, rectangular structure. This makes the product blend into its
environment due to it’s unobtrusive design. The simple design
and colors make the product additionally blend in to the
atmosphere. The product again would be cheap to produce and
buy due to the cheap, reusable materials. This also makes the
product environmentally friendly as it can be reused at the end of
its lifecycle. In addition the soft materials makes the lamp safe.
This is an advantage as it protects the product consumer from
risk of hurting themselves on it. In addition the design is thin and
tall. This is suitable as it can fit in small places. In addition, its
light weight, thus meaning less stress if needed to be moved by
the owner.
This multi-purpose lamp and storage holder stands
out and is efficient. The bold colors and retro
design on the lamp makes it stand out and
aesthetically pleasing. The lamp would be costly
due to the material used, which is metal. The
product is not environmentally friendly which is a
disadvantage. However one thing I like, and that
could inspire my design is the multi-propose
function, the retro-design and the bold, simple
colors. In addition the size is just about right. Its
small enough to sit on a bed side table, however
big enough that it produces quality light, and can
hold things in the bottom. In addition, the bold and
simple colors make the product suite lots of
environments. Moreover, there would be a large
target market. Older people may be attracted to this
design due to its design, and efficient multi-propose
function. However, kids may be into this design due
to the bold and attractive color scheme.
The simplistic colors stand out to the target market. This
opens the target age range to approximately 4+. The
products materials are metal and wire. This type of sheet
metal would be easy to cut through CAD/CAM on the
laser cutter. This means that the product would be
suitable to produce in mass in industry as you can also
use a template. However the product would be costly due
to the unsustainable materials used. But, due to the easy
manufacture the price would be reduced. Moreover, the
product is aesthetically pleasing due to the smooth and
shiny appearance. This makes the product look tidy,
however also childlike. The product, however, may only
suit some décor in houses as the bold colors could
contrast to the wall and other features in the house. The
lamp hangs from the wall. This means that the product is
out of the way. This in effect is an advantage as there
would be no taking up of space. However, this product
would be very difficult to make in the internal environment
and facilities that I have at school.

Research into existing products
This speaker is not so aesthetically pleasing,
however is perfectly suited for it propose as a
portable speaker. The product is small in size and
light weight. This is an advantage as it is easy to
carry around and not a hassle. In addition to this,
due to its size it can fit
anywhere in the room, however limiting the ability to project a large sound.
Paradox to this statement, the sound quality is very good and loud. The
aesthetics of the product is let down by the use of material. The material is
some sort of mesh wire. This makes the product unappealing and cuts down
the consumer market. However some may take the size, shape and quality
into account, thus becoming appealing to that particular person. Furthermore,
the product can probably be mass produced and would be relatively cheap.
This is due to its use of materials, as they are not that high quality. Moreover,
the product is very safe. This is due to the rounded edges and shape, making
it safe in means of an accident. Lastly, the product is not sustainable due to
the materials and components used. This means that it may limit the
consumer market more, as it is harmful to the environment.
This speaker is both aesthetical pleasing and
sustainable. The product is made out of, what appears
to be beech wood, and wood is the most sustainable
material on the planet. This shows that the product can
be reduced, reused and recycled. The aesthetic appeal
comes from the materials smooth finish and tidy look.
We can infer that the
product is in the shape of a medieval symbol, however, can also be inferred
from children, as an animal, such as a whale. This opens up the target markets
as the unique, yet familiar portrayal of the speaker is appealing. In addition to
this, due to the wood, it can suit almost any décor, fitting into any environment.
In addition to this the speakers are small. This allows them to be placed in
small area. However, because it comes in two, the product as a whole could be
a hassle to carry around. However this increase the quality of the speaker. The
cost of these speaker would be moderate to high, due to the quantity and
quality of the materials. However there is little material being used due to its
size, thus decreasing the cost. The product may be manufactured in batch, as
its good quality, therefore increasing the price again. Lastly, the product has
rounded edges thus making it safe.
This product is more or less aesthetically pleasing, it
depends on what style you are attracted too. The
product is very expansive due to its size, the
materials its made from and manufacturing process.
The target market would be 10+ due to its size, and
sound production.
The size is very big and heavy, and would not suit the purpose of being
a portable speaker system, however it would produce very good sound.
The materials it is made out of are not very sustainable and
environmentally friendly, however could be reduced. By reducing the
size and waste of materials. In addition to this the manufacturing would
be time consuming, therefore increasing the cost of the product. Lastly,
we can see, that by the rounded corners that the product is safe.
However, due to its size and weight it does increase the risk of harm to
the consumer.
George nelson’s marshmallow sofa is
aesthetically pleasing, and may inspire the
designing of my product. The chairs circles and
bold, yet simplistic design and color scheme,
leave an noticeable effect on the consumer. The
consumer market could be
aimed at children and adults, due to its post-modern and unique
design features. The product may be high at cost due to the extensive
amount of material used, due to its size. The inspiring aspect of this
design is the ‘marshmallow’ effect. They look and feel soft and fluffy,
suggestively leaving the viewer happy. In addition the color of red can
be inferred at symbolism towards desire and love, automatically
putting someone in a good mood. I saw this in a live Hong Kong
exhibition.
The design movement ‘De Stijl’ may also be an
inspiration in my design. I feel that the neoplasticism
style is eye-catching, and the bold color scheme would
draw immediate attention to the product. This may
inspire patterns and color in my design. The consumer
target market for a product which incorporates this
style, could rage from 5 and onwards, due to the playful
color scheme, in contrast to that mature, sensible
structural pattern of straight lines.
Own Photo’s

Materials, components and adhesives
Material Properties Use in my project
Epoxy resin (Araldite) • Hardens as a second chemical is added
(catalyst)
• Sticks acrylic to any other plastic
• Very strong
• Apply to acrylic side
Advantages: Once applied the glue has a high water resistance. This is an advantage if the
product is in the bathroom or left outside in the rain, the materials will stay strongly intact without
ware, increasing durability. The resin can also be hidden by wiping it off whilst wet. This
enhances the aesthetics making the product still look tidy.
Disadvantages: The resin is costly and more expansive then other glues. This makes the overall
product more expensive, being inconvenient when sold, potentially lowering the target market.
The glue also has to be mixed up. This is time consuming adding extra work.
This particular resin would be suitable for my product as its strong, making the product more
durable; also it can be used to stick acrylic to any other material, such as H.I.P.S or wood. This
allows the product to include a range of materials fitted together with strength and enhanced
aesthetics.
liquid solvent cement • Solvent evaporates and the adhesives
harden
• Strong for short period of time
• Sticky
• Residue is brittle
Advantages: The rubber base of the cement is a thermoplastic. This means that when heated it
can be remolded. This enables reusing of the material, making the product more environmentally
sustainable. It’s also easy to use to join two materials together. This makes the proses less time
consuming. In industry this means there is less working time meaning that the product is more
cost effective to manufacture. The glue will also come of the surface easy, thus meaning it can
be cleaned up easy. This will allow the product to look tidier, enhancing the aesthetics of the
product.
Disadvantages: The property of rubber being a thermoplastic means that when the glue comes
into contact with heat it will soften. This limits what can be around this product, reducing is
versatility. The glue will also lose its ability to stick over time. This means that the use of this
adhesive is not durable and sustainable; thus making this type of glue less effective and
appropriate for the manufacture of a product.
The properties of rubber as a thermoplastic reduces the capability the adhesive has to be around
hot materials. This property makes the solvent unsuitable for my product as the light may come
to high temperature, putting the solvent at risk of melting, making the product lose support from
the glue.
Vinyl • Durable
• Wear and water resistant
• Economically sufficient
• Recyclable
• Can be cut using CAD/CAM (2D design
and the vinyl plotter)
• Shiny
Advantages: Due to its synthetics its very durable. Vinyl can last up to 100 years, this means that
it wont wear and can maintain its aesthetics for a long time. Moreover, this material can be
recycled as it is classed as a thermoplastic, meaning it can be reheated and reshaped. This
makes the material more environmentally friendly. This material is also the cheapest plastic and
it is easy and quick to manufacture. This means that it can be used in abundance without making
the product of a high cost.
Disadvantages: Vinyl is a synthetic man-made material. This means that the manufacture of vinyl
was done on an industrial scale. This increases its environmental impact, reducing its
environmental sustainability.
This material is suited for my project as it has many advantages and good qualities. It is a
suitable material and is very aesthetically pleasing, thus could be used as sticker, etc…
A Sustainable material is a material that obtains social, environmental and economical benefits; protecting the environment from harm during its life cycle,
from extraction to decomposition. Testing theses materials, components and adhesives will allow the manufacturer and designer to gather ideas of how the
product will be constructed to better its function; also deciding what is suitable to manipulate successfully.

Materials testing (Plastics)
Material Uses Properties Manufacturing process Advantages/Disadvantages How could I use this in my product?
Acrylic • School
workshops
• Signs
• Light casing in
cars
• Bathtubs
• Resistant to most
acids
• Weather resistant
• Brittle
• Hard/Difficult to cut
by hand
• Drilled using pillar
drill
• Bent on strip
heater
• Twisted by heating
material in the
oven
• Finished by hand
using 2nd hand cut
file , then wet and
dry (carbon paper)
• Shaped using belt
and disk sander
 Advantages of acrylic would be that its
environmentally friendly due to the fact it’s
a thermoplastic, meaning it can be
recycled by reheating. In addition its
weather resistant properties means that a
product made from this material can be
used in and out doors ensuring the
prevention of damage. , With the use of
CAD/CAM its quick and can create a good
finish quickly
 A disadvantage of acrylic is that it is
difficult to cut by hand. Moreover, even
though its strong it is brittle. This makes it
more like that the product will snap and
break.
In my product I will use acrylic with
the aid of CAD/CAM using 2D
design and the laser cutter ;
ensuring a high quality appearance
and accurate cut. I may also use
wet and dry carbon paper on the
edges to maintain a shiny, smooth
finish. In addition I could use the
strip heater and oven in order to
fold , twist and or bend my product
into a correct shape. To make sure
this is accurate I will use a former
to mould my material around.
H.I.P.S • Computer
housing
• Cups
• Instrument
panels and
fittings
• Glossy and
attractive
• Strong
• Can be moulded
easily
• Lightweight
• Resistant to
chemical damage
and weather
• Takes a long time
to deform under
heat
• Injection moulded
• Heated in the
oven; twisted and
folded
• Bent on the strip
heater
• Drilled on the pillar
drill
• Moulded in
vacuum former
 The material is rather heat resistant and
hard, using it in my product will ensure
durability. This is an advantage as it allows
the plastic to last a long time, then at the
end of its lifecycle it can be reheated and
moulded into another product. An other
advantage is that it has a glossy or matte
finish. This gives the material and the
product and aesthetically pleasing look.
 However a disadvantage to the material
would be that it s difficult to manufacture
by hand as its very strong and hard to cut.
In my product I will use the HIPS
on the vacuum former or in the
oven to form a more fluid bent
shape, rather than the rigid bend
that the strip heater produces. I
can then cut out the final shape
and sand it down using wet carbon
paper to enhance the aesthetics,
leaving a smooth and neat finish. I
will also polish the plastic to ensure
a glossy finish, enhancing the
aesthetics further and dust of
excess material that may linger
after the cutting or sanding
process.
Polypropylene • Blows
• Packaging
and casing
• Pipes
• Stiff
• Chemical resistant
• Flexible
• Heats quickly
• Light
• Bent on the strip
heater
• Cut on ban saw
and laser cutter
• Drilled using pillar
drill
• Heated and rolled
into ball in the oven
(unintentional,
heated to quick)
 Advantages of this material is that its
flexible allowing it to fold around a product.
It is light weight allowing easy portability.
In addition it allows light to pass through,
therefore would be good for the shape on
a lamp.
 A disadvantage to PP is that its low heat
tolerance restricts the versatile use of the
material in relation to my product. In
addition its not the most aesthetically
pleasing material thus giving a poor finish.
In my project I could use
polypropylene as a cover over my
lamp. This would look aesthetically
pleasing as it allows the light to
pass through. In addition
polypropylene is flexible therefore it
can be wrapped around the lamp.
Polypropylene is also easy to cut
using CAD/CAM,; this will be
efficient when cutting it to fit my
product making the cut accurate
and clean.

Materials testing (Wood)
Material Uses Properties Manufacturing process Advantages/Disadvantages How could I use this in my product?
MDF • School
worksho
ps
• Furniture
• Buildings
• Looks good
• Hard and
smooth
• Easy to cut
by hand
• Can be
painted
without an
undercoat
• Drilled on Pillar
drill
• Cut on the scroll
saw
• Sanded using
glass paper
 Looks good when cut, even by
hand. In addition it is easy to cut
and drill into because its soft and
not dense. This also means its
light therefore it can be picked up
and moved easily.
 Damaged easily by water and
weather. This means that it will be
bad if the product is needed to be
placed outdoors. In addition its
not the strongest material
MDF can be used in my product as a stand.
This can be made to look aesthetically
pleasing as it can be painted. This allows the
product to have a strong base whilst also
looking good with a colour frame. The MDF
will be cut using coping and tenon saws,
then filed down. Glass paper is then used
sand the edges, This will make the MDF
look tidy and pleasing to the eye.
Plywood • Flooring
• Wall
panelling
• Furniture
• Flexible
• Easy to cut
• Less likely to
warp and
split
• Strong
• Scratches
• Holes drilled on
the pillar drill
• Cut using the
copping saw
• Filed using 2nd
hand cut
• Sanded using
glass paper
 An advantage is that when
working with the wood it is less
likely to warp; this property is due
to it construction where different
materials have been layered on
top of each other with synthetic
resin in order to make the
structure stronger.
 A disadvantage of cutting this
wood is that it is likely to split in its
layers and splinters easily. This is
bad when making as it take longer
to get a good quality finish.
I can use this in my product as a base due
to its strong properties. The plywood could
be cut either on the ban-saw or by hand,
Thin plywood, called flexi-plywood, can also
be cut using CAD/CAM in the laser cutter,
making a cleaner and more efficient cut. To
ensure enhanced aesthetics file then sand
using glass paper, however, avoid
splintering the wood. To enhance the overall
aesthetics more apply a clear varnish or
wood stain. This will also protect the material
preventing further splintering and warping of
the wood.
Oakwood • Flooring
• Quality
furniture
• Interior
wood
work
• Tough
• Hard and
strong
• Open grained
• Aesthetically
pleasing
• Natural
timber
• Drilled on pillar
drill
• Cut on ban saw
and by hand
• Sanded using
glass paper
• Filed using 2nd
hand cut file
 Advantage of oak would be that
its very strong with a good quality
finish, looking aesthetically
pleasing. Oaks also the most
sustainable as it is pure timber,
meaning that its environmental
impact it very small.
 A disadvantage of Oakwood is
that because its hard and strong
its difficult to cut by hand and
takes a long time to file and sand
by hand.
Oakwood in my project could be used as a
base. This is due to its strength and
durability being able to withstand different
weather conditions. In addition it is easy to
get a nice finish using varnish. This will
make the product look aesthetically pleasing
whilst also practical as the varnish will
protect the wood from water (humidity and
rain) and rough surfaces (to some extent).

Ergonomics and anthropometrics
Anthropometrics is the study of the size of a product in relation to the size of the person or counter product. Anthropometrics refers to physical
anthropology; where the measurements of the human fits into the purpose. Whereas ergonomics is the relationship between the anthropometric
data, the person and the product. I will use the anthropometric data to:
 Guide the shape and size of the speaker/lamp, so it is comfortable for people aged 8+ to use
 Ensure the weight of the product and its size is suitable, enabling it to be held and carried easily
 Ensure the holes for the speaker are in tolerance; e.g. 2mm smaller than the actual diameter, to allow for gluing and so the speaker does
not fall through the hole
 Make sure the light hole will be exactly the same size as the diameter so it can fit snugly into the hole
 Calculate the base surface area of the lamp-speaker so it does not take up too much space on the desk
 House the circuit and battery inside neatly so they cannot be seen and have enough air to circulate around them so they do not overheat
Product Size: Height/depth (mm) Weight (g) Area/diameter (mm x mm)
Speaker 15 10 Diameter 50
Lamp 17 13 67 x 76
9Volt Battery 17.5 8.6 26 x 28.8
Space where It will be
placed
N/A N/A 19.7 x 20
19.7mm
20mm

User profile
Name; Toby
Age; 16
Occupation; Student
Interests; Listening to music, gaming, bb gunning.
Description of design requirements; Simple, colorful
Cost limitations; £10-20
Desired product outcome; “I would prefer the product to be easy to use, simplistic, and
produce good sound.”
Name; Tom
Age; 24
Occupation; Graphic designer
Interests; Media. Modern art
Description of design requirements; Quirky design, modern
Desired product outcome; “I would like a cool and quirky design, flowing with color and
bursting with energy. I would also like that quality to be perfect, with an aesthetic appeal so that
I will be intrigued to use it.”
Name; Kate
Age; 42
Occupation; Lawyer
Interests; Modern and classical art,
Description of design requirements;
Desired product outcome; “I would like a design that could incorporate my interests, neat and
eye catching. The design must also produce excellent sound and light quality”
The user profile is used to get an idea of what the products target audience likes and dislikes in a product. This will ensure the product is suitable and appealing for the
range of people that the product is aimed at. This will enhance the sale of the product in industry. The people who I am aiming my product at are similar to the ones below:

Analysis of research
Research into existing products
→ The average speaker would cost around £30-50, and the average
lamp would be around £10.
→ The materials the speakers and lamps are normally made out of
are wood and plastic; as these materials would suggestively be
easy to use and cut, durable and are environmentally friendly.
→ When speakers and lamps are brought they are purchased as a
whole and are not ones which need to be assembled at home. This
means that the assembly needs to be perfect when manufactured,
using glues and adhesives to make the product strong, as well as
the product needing to be small and light weight in order to move
from one place to another.
→ Most products have designs and colors that are simplistic and
quite plain. Inferring that this is a common theme as it is the most
popular and aesthetically pleasing; I will take this into account
when I design my product so it matches the competitive market.
→ All the lamps and speakers are fairly small so they are light weight
and not using to much material, fitting my idea of how I will
construct my design.
→ Design eras influence previous designs, therefore this will be
shown in my work. I have researched 2 design eras which I am
influenced by, De Stijl and Art Deco. This will be apparent in my
designs. George Nelson’s work could possibly influence some of
my designs as it is a popular and quirky brand.
Ergonomics and anthropometrics
→ Need to consider the size of holes and spaces. This allows accurate gaps to be
measured to the correct mm, give or take 2mm for tolerance, for the space needed
for the 9V battery, the light and speaker component, and the maximum space that
my product can take up.
→ Important as it allows the dimensions to be accurate when cutting holes to fit
components needed such as the light, lamp and battery pack.
→ I will use the measurements taken when trying to layout my design to allow the
components fit efficiently, maximizing the use of my product.
User profile
→ All have the same thought of simplicity, this can be inferred to be
the most popular theme thus selling the best. Therefore when
making my product I will take these ideas into consideration.
→ Most people are willing to pay £40 as it is a reasonable cost for a
lamp and speaker set; not too expansive for its size in relation to
the function.
→ In my product I need to take this into consideration when choosing
materials and the cost (if I was to sell it in a shop).
→ The target audience likes different aspects of a design; in relation
to their age. This will give me a better understanding on how to
make it fit everyone's likes and attitudes, from people in different
facets of society.
Materials, components and adhesives
→ The cheapest and most abundant plastic material that can be used in my project is
vinyl, so I will include this, but not too much as it cannot be recycled.
→ There are many advantages of this material that can ensure a high quality finish in
my product, thus making the product more appealing. This allows the product to
compete in industry.
→ Vinyl is also the cheapest material that can be worked with in the workshop. This
means that it will be used in my product as it is cost effective, meeting the
demands of the specification.
→ The best adhesive to glue acrylic to another material is epoxy resin.
→ This is the most effective and will ensure that the design is efficient in meeting the
needs of the specification.
Material testing
→ The strongest materials are the natural timbers and HIPS. This is an advantage as
they are less likely to snap and break when used in a product; ensuring durability.
→ The most sustainable product is the manmade boards, however all the materials
used are sustainable, making the product environmentally friendly
→ Most of the plastics have a high heat resistance. This will allow forming. This
method can be used in my project to create a specific shape to my product.
→ Polypropylene is practical for a lamp shade and is often used for this. This is
because the material is flexible and also light is able to pass though making it look
aesthetically pleasing, giving off a warm light.
→ In my project I will choose the materials that look most aesthetically pleasing, the
ones with the least impact on the environment, and the materials with portray
simplicity and practicality.

Design specificationMy design must:
 Appeal to a Target market of ages 8 years and onwards; both men and women. This is because there is a large percentage of people who listen to music, however if younger than 8 they may not be
as capable to use this technology without harming themselves and or others. To ensure this target market is portrayed in the product the design must be kept simple yet unique and mature.
 Be suitable for any Religion and race, and will not contain any offence signs (i.e.. R18 material or the swastika) that could offend a particular facet of society. Thus making the product open to any
religious beliefs, respecting each individuals values. To do this the product will be kept simple and mature.
 Meet the demands of the Purpose; to project a good quality sound and light, in order for the consumer to read in the dark, and listen to music anywhere, as it will be portable. To ensure this the
product must be light in weight, able to withstand different weather conditions and easy to use.
 Suit the Environment that the system will be in; which is not limited. As it is portable and due to its purpose it should be able to be place on a bedside table and or counter. However, also needs the
stability to hold its self up on the floor, or other places on the ground, whether it is inside or out.
 Be limited in Size in relation to its environment, and the conservation of the environment. The product must be small enough to fit on a small table, or equivalent space on the floor. In addition the
product cant be too big as it needs to be able to move around as a portable devise.
 Ensure that it is light in Weight. This is related to the purpose and target market. Due to the fact it should be a portable speaker system with the age limited to 8 years and above, the weight of the
product must be kept small so that it is easy to carry around and move. To do this the materials used must be somewhat light (i.e. MDF, acrylic).
 Establish good Durability of the, as the product should be expected to last around 3-4 years. The product must be durable as it may be found in spaces where its knocked around or placed on a rough
surface, thus preventing damage. To make the product durable I will use plastics that are strong, however not brittle, and resistant to wear. I will also use woods coated with a finish to ensure quality
and prevent damage and wear.
 Have Aesthetics limited to plain and simplistic patterns, however bold colors, as its suited for such a wide range of people, it needs to be appropriate for everyone. In addition, it needs to suit any
environment its in. The look should be simple but effective as the product needs to take into account maturity and offence when put on the market to compete.
 Be made out of Materials that have a range of functions. Such as, lightweight, waterproof, fireproof and strong. This will contribute to the products durability and use. To ensure this the product will be
made out of wood, with a finish or varnish, and a plastic such as HIPS, acrylic or vinyl for colour and durability.
 Acquire a relatively cheap Cost that is affordable for the range of the large consumer market. Therefore, the materials must additionally be cheap. This will allow the product to compete on the market
and be made easily in industry on a large scale without being too costly. It should cost no more than £15 to manufacture, so it can be sold for a profit.
 Take into account Environmental issues. For example, the materials used must have the ability to be reused and recycled to form another product. Moreover, the waste of the materials must be
minimal. Furthermore, the materials chosen must be the most sustainable materials that are available. To ensure this the product will be made out of thermoplastics and sustainable wood. Such as, but
not limited to; Acrylic, H.I.P.S, MDF and beech wood.
 Be suitable for Mass Production in a factory or workshop., however the product that I am making is a one off prototype. Therefore, the product must include elements of CAD/CAM to show that its
suited for this Manufacturing process. These elements will be incorporated by using the 2D design, the laser cutter and vinyl plotter; using materials such as acrylic, vinyl and polypropylene.

Initial IdeasTranslucent
acrylic plate on
top to hold a
phone devise,
like a table.
Held on with a
araldite
adhesive.
Hole in the
middle of the
plate to pass the
connecting cable
through. Adding
a clean
appearance so
the cables do not
look messy.
Holes drilled out around
the top to allow some light
to shine out, almost like a
disco ball effect. This
could add contrast
between the old medieval
design and the retro,
modern shine of light.
Body is bent/curved
around a mould in the
vacuum former or once
heated in the oven.
Made from HIPS due to
its durable nature and
bright colours.
Acrylic feet on the bottom to
prevent scratching on surface of
ground and product, making the
product more durable.
Based on a medieval theme that is
shown in my research.
I like this design because of its
medieval theme, I think that it is an
interesting design that is rather
eccentric, however the design doesn't
suit the modern simple design as
outlined in the specification and it’s
childlike qualities might be off putting
to some purchasers.
I have ranked this a 5/10 as
many peopled asked feel it
would be rather difficult to
make and not very popular in
my target market due to it’s
childlike qualities.
Top part holds the light
fitting which can be
purchased from IKEA,
and the holes allow the
light to be emitted out.
Sheets of acrylic for the walls,
using a comb joint to connect the
4 walls. This will be cut on the
laser cutter as it will give a
smoother, professional finish.
Liquid solvent cement can be
used to glue the joints together,
giving it a strong, durable finish.
Middle shelf is for
storage of CD’s and
devices such as a
phone. To connect the
phone to the speaker
there will be a hole
which can hold the
aux cord. The bottom
compartment will hold
the speaker circuit
and component.
Shelves between each
level to hold
components and
separate the selves.
This will be made from
acrylic and glued onto
either runners or
engraved grooves for
the shelves to slide
into.
Acrylic feet on the bottom
to prevent scratching to
surfaces and product.
I like the design due to its minimalist style. It is
simple and suggestively easy to make. In
addition it should be inexpensive due to it being
made using acrylic, which can be recycled at the
end of it’s life cycle. This style suits the needs of
the audience and I feel that it is an appropriate fit
to the specification as it meets all of the points.
8/10
45mm hole for speaker to fit into, preventing it
from falling and breaking whilst using the
product.
Vacuum formed around a wooden cone shape mould using HIPS, as it
is durable and wont heat fast under the light, thus makes the material
safe and easy to shape.
Two separate compartments using a slit screen
made from acrylic or polypropylene sheet. This
will allow the components to be hidden and to
prevent internal damage by components sliding
around and breaking.
Legs made from wood that have
been glued or screwed internally to
the speaker casing, allowing the
speaker to project outwards rather
than downwards.
I like this design as its almost promoting its function as you
can suggest it looks like a microphone. I took inspiration from
George Nelson’s marshmallow couch, which inspired the idea
of food and candy leading me to the idea of an ice cream
cone.
This design is suitable and complements the specification
as it is simple, however the holes may make the design
appear too complex, thus this product is a 6/10. Actually
making the 2 halves of the moulds meet neatly may also be
a tricky process.

Initial IdeasHandle, aid for easy
portability.
Feet elevate the speaker
casing off the table
giving it more shape and
style, plus preventing
damage to the surface of
table or the base of the
speaker.
The design looks
retro with it’s simple
shape and is
inspired by the forth
existing product. It
is also simple thus
suiting the target
markets
preferences. This
would sell well if
mass-produced as
so have many
others like it. Small table off the
side made from
acrylic, bent to give
space for screwing
in place. This will
hold the phone or
music device, with
a hole for the aux
jack.
Frame of the speaker
made from hard wood,
such as beech with comb
joints to hold it together.
This will enhance the
appearance, making it
aesthetically pleasing and
durable. In addition a
wood dye and bees wax
finish could be added to
enhance the overall grain.
Small so that it can
be light weight and
easily portable. This
matches the
specification making
the product suitable
to make. In addition
the frame is wooden
which is a
sustainable and
environmentally
friendly enhancing
it’s overall appeal to
some consumers.
The product matches the specification, looks classy and
suits the target audience. The product is not to complex
to make and can have a beautiful finish if cut out,
assembled and finished correctly. 6.5/10
Symmetrical design making the pattern look simple. This will appear
to the target audience as simplicity is found attractive in a product.
Streaky designs
made from vinyl
stickers cut on the
vinyl cutter, (CAD).
Inspired by the idea of a juke box linking to
the retro theme.
Feet allow the
bottom of the
product not to get
ruined from the
environment
stored in, also
adding a juke box
style base the to
design.
The design is small and
light, this can be easily
portable.
Translucent acrylic frame
bent around a curve by
oven forming, this will allow
the internal components to
be seen. Then an opaque
front and back made out of
acrylic using the laser
cutter.
6.5/10
This design links to the retro theme as it is in the style of a juke box
which was a very popular product in the 1950’s. However this product
is smaller. The product may not suit the design preferences as its not
too simple. It also contains 2 speakers and a light making the product
more costly and heavier than before.
Sunk in hole to hold the device without it
slipping off the surface of the product when
connected to the speaker.
Hole at the
end of the
sunk in one for
the AUX cable
to pass
through
3 thick layers of acrylic at the top to enhance
the overall colour and finish, with the holes cut
on the laser cutter (CAD) for the speaker and
other sunken holes needed.
No lamp thus not matching the
specification, however an extra
speaker is added for a more
amplified sound and improved
aesthetics.
Small and preferable made out of either plywood, beech or MDF, thus the product will be light weight. The base would need to be hollow to hide
all the circuits and wires, so will need a trap door of some sort to access the battery. This shows compatibility with the design specification thus
being an appropriate design.
I like this product design as it is simple and I believe
that it would sell well; It pleases the target audiences
preferences with its minimalist designs.
8/10
The design does not however have
a light, therefore it doesn't fully meet
the specification.

Initial IdeasThis is the favorite design of
3 others and myself, due to
its unique aesthetic appeal
and smooth texture. I will
develop this design idea.
This design is based on Dale
Chihuly’s unique glass moulding
work in the Bellagio hotel in Las
Vegas. Difficulties in making
this product will be
getting the holes to
be exact once formed
as the heat may
change its shape and
size.
The speaker and light
components are placed
under the hole with a
layer or plastic
underneath to make the
device portable without
the components falling
out.
The shape will be casted using modelling clay and will be
moulded out of HIPS on the vacuum former. If the modelling
clay is frozen over night, it should be more resistant to the heat
when being shaped. A base would be needed to help store the
internal components if developed.
9/10
I like this this design
because it is simple and
also unique, thus has a
bold appearance. I think
the design appeals to
the target market as its
complex design leaves
a simple, effective look.
Round to enhance the aesthetics, whilst also preventing risk of
injury to consumer if one falls on the speaker.
Can rest phone onto
of the two legs used
as stands.
Stand/feet
used to
increase the
stability of the
product,
making it more
durable, also
adding to the
aesthetics.
Front frame made
of MDF with an
internal hole cut
out for the
speaker
component cut on
the scroll saw and
laser cutter. Then
wrapped around it
a narrow slip of
translucent
polypropylene cut
using CAD/CAM.
I like this design as it is simple and bold,
appealing to the target audience whilst if
placed in a home would not draw too much
attention away from a main center piece.
The design is small
and suggestively light
weight. The wood and
plastic are sustainable
materials, thus making
the product
environmentally
friendly. The light
could be stored at the
back of the speaker
giving off a dull mood
light. 6/10
Translucent polypropylene lamp shade,
to allow light to pass through with a soft
glow into the room. Cut using the laser
cutter, then bent and folded using the
strip heater.
Hole between
compartment and
speaker to allow the
AUX cable to connect to
the device.
Feet at the bottom of
the product to prevent
scratching on
surfaces of floor and
base
Rounded edges on the
product to prevent injury to
user
The base could be made
from wood such as MDF or
beech, or a vacuum formed
HIPS base would look
bright, bold and colourful
plus hold it’s weight. Plus all
could be drilled into quite
easily for the speaker hole.
The product is not that practical as it would be difficult to be portable as it holds an
awkward shape and would not be too light. In addition the cost would be relatively high
due to the amount of material used and the different processes needed to make the
product.
I like this design as it can hold
extra appliances and device, thus
being a multi functional design.
The aesthetics are pleasing due
to the simplicity of the design,
however the making will be rather
complex and time consuming.
Many people like this due to it’s
originality, however I prefer the
design above and think it has
more flair and potential.
8/10
Light shines down on the phone stand
Stand made out of wood, assembled
with comb joints, finished off with files,
sand paper and bees wax for a sleek
and stylish appearance.
Phone holder, 2mm
tolerance to phone
depth. Avoids
phone slipping of
surface of wood
without breaking.
Inspired by a modern speaker lamp, this lamp shows
minimalist qualities. The design is tidy, simple and
aesthetically pleasing.
I like this design as it is simple but
looks effective. Vinyl stickers may
be added for extra appeal.
This design is very
aesthetically pleasing
and definitely suits the
preferences of the
target audience. In
addition this product
would be easy to hold
and grip thus matching
the specification.
However it may be
difficult to hide the
speaker circuit and
components due to the
thin design.
8/10

Modelling and Testing
After finally modelling the perfect top, when
placed on the base it looked too symmetrical and
does not capture the organic beauty of Dale
Chihuly’s glass work. The regular pattern limits
the designs organic and fluid shape. I will add
more irregular bumps and waves in the base to
correct this.
Testing a design is very important when planning to make a product. This is to see the product in perspective with the correct dimensions and style to see if everything fits
together accurately, to adjust or amend proportions and see if the design is aesthetically pleasing. This is the part where adaptations and modifications are made to the design in
order for the product to function properly. To model the speaker casing I used modelling clay as this will be the material I use to make the vacuum forming mould as it is simple
and easy to shape into this beautiful organic design.
I then modelled the base so it was solid modelling clay. When the base was
modelled using the clay, measurements were taken to ensure that it would fit
into the base of the vacuum former. Even though I took the measurements,
the initial model was too big to fit into the vacuum former, plus it would have
taken up too much space on a table top. I modified the shape, making it
smaller and more oval which enhanced the aesthetics. I made the design
40mm diameter smaller to ensure it is light, small, easy to maneuver and it fits
into the vacuum former.
When moulding the modelling clay there were bumps and finger
smudges. I realised that these marks would be outlined when put
in the vacuum former. I put the clay in the oven for 20 seconds
and melted the outside to try and achieve a smoother finish. This
helped achieve a smooth appearance on the outside of the
shape, along with rubbing the surface smooth.
After modelling the first speaker top and testing it to see if the speakers fit
comfortably, I found that this design was too short. So I made it 40mm taller
to accommodate 2 speakers and the circuit underneath. When tested this
now fits both speakers, the circuit board, a 9V battery and the small IKEA light
sensor comfortably underneath / inside.
After testing modelling the base, I tried to make the shape of the base
so it was irregular and fluid. I then realised that this design would not
be appropriate to place in the vacuum former as the flat structure would
not support itself and most likely collapse when heat and pressure is
applied by the vacuum former. The base therefore needs to be
completely solid when vacuum forming to avoid this. I will make this
change.
On a flat piece of scrap HIPS I tested, using a forstnerbit,
the size of the hole for the speaker and whether it was
easy to cut out or not. It turned out easy, therefore I have
come to conclude this is the method I will use to cut the
speaker holes. However, this is not a true test as the
actual hole cut from HIPS is from a curved shape so it
may prove to be more difficult when drilling.

Modelling and Testing
I tested out the vacuum former on a smaller shape, similar to the shape of the top of my product. The settings
were all set to full and the timer was set to 60 seconds. This was successful and I agreed these were all correct
setting. This was then decided, the way I was going to produce my final product ensuing success. No alterations
to the setting needed.
The shape was put in the freezer for 12 hours over night. This made the modeling plasticine stronger, reducing
the chances of meting when heat was applied. However, before the mould went into the machine it sat out in the
warm air for about an hour. This may have reduced its strength to maintain shape and form. When the real
product is made the time of transfer between the machine and freezer will be kept minimal. This will ensure the
size of the moulded plastic is kept precise.
Excess plastic was cut off with approximately 3mm left around the cap. I then filled, using a half round file as the grain is smoother
thereby leaving less scratches on the plastic and giving the plastic a less likely chance of cracking. Then I sanded the edges using wet
carbon paper. This smoothed the plastic and eliminated the crates left from the cut and file stages.
Once the vacuumed shape is created the next test was being able to take out the modeling clay. To do this I
originally used a spatula, however, this was ineffective as the clay stuck in tiny lumps, formed by parts of the
uneven surface, would not fully come out without leaving marks. To fix this problem I used a paper towel. The
paper towel is environmentally friendly as the paper is made out of trees and much is used, reducing waste. The
paper towel was then used to rub the plastic taking of the excess clay and polishing the material.
Test legs were glued onto the 3mm lip of the HIPS cap shape using liquid solvent cement. The legs were tested using 5mm and 3mm
thick acrylic. I tested using different colour circles that were found in a scrap box, used from previous projects. I was reusing waste
material, making my testing more environmentally friendly. The circles were glued together using liquid solvent cement and were strongly
glued in place. This looks aesthetically pleasing, especially with the alternating colour pattern. However, if one layer of the feet fall off not
only will the product become unstable, but the surface of the acrylic doesn't look very tidy. This is because when the liquid solvent is
applied on the acrylic, the plastic is melted, thus you can see a white stain mark left on the plastic. I need to be super careful when
applying liquid solvent cement to my work.
I drilled holes in 3mm HIPS, the same as I use in my product, to test what size drill bit is needed to drill the holes into
my base to fit the 10.2mm bubble rod. I tested 2 sizes, 6mm and 5.5mm. I then tested them by putting the bubble rod
through and determining weather it was a tight fit or not. The 5.5mm hole fit perfectly, not to tight or loose. Thus this is
the drill bit I will use.

Final design
The overall function of the design is to provide a good quality speaker and light that was easily
accessible. I will make this design to suit these functions, to ensure the specifications demands are
fulfilled. The black casing will hold two speakers in either side, therefore producing sound from all sides
of the product. The black hips will be cleaned using meth's, but no finish will be applies as it is plastic.
The black HIPS casing will attach to the base with acrylic rods that will run through the acrylic base using
a dowel joint. This means that the casing is secure from being knocked over and damaged, also close to
the base where the speaker cable can connect to the phone with barely any wires showing lose. This
keeps everything tidy and reduces any hazards, like pulling out the cables and ripping the circuiting. The
dowel will be glued using liquid solvent cement and the speaker to the HIPS will be glued using araldite.
The speaker mesh will be made from layered acrylic that had been glued using liquid solvent cement,
then sanded on the belt sander to contour the HIPS shape. The mesh will be glued using araldite.
Underneath the HIPS casing there will be a plate that has been attached to the base. It will be a
functional plate that will slide in and out of a slit on the end of 3 half lap jointed rods that have been glued
to the rim of the HIPS, using araldite. The end of the rods that will be seen will be sanded using wet
carbon paper to add aesthetic appeal and sophistication.
Overall, I like this design as its shape can be interpreted in many different ways by different types of people. This means that I can suit a large target
audience, fulfilling the criteria for the design. In addition the speaker, light and phone holder will allow functional capabilities that will mean that there
is a clear purpose to the design, in addition these features add extra aesthetic appeal. The color scheme is black and green making the look more
simple in contrast to the complex and unique shape design. A small amount of plywood will be used keeping the product environmentally friendly
and cost effective; however a lot of plastic is used. The plastic used is thermoplastic, thus meaning it can be heated then reheated again. This
means that the product materials are environmentally friendly as it can be reused after one life cycle is complete. To reduce further environmental
impacts I will reduce waste of materials and appliances.
The base will provide the light. This also meets the demands of the design specification. Layers of green
light gathering acrylic will be layered to form a casing for the lamp, this will support the lamp to make
sure it is not knocked off and damaged. The LG quality of the plastic means that when the light is shining
through there will be an added glowing effect. The light will face down, thus shining into the acrylic. This
will support the products aesthetic appeal. The acrylic base will have a hole cut out to fit a IPhone 5. This
slot will be lose so that is the phone has a case, which from a census most did, it would still fit
comfortably. This holder will support the phone so that it is kept close top the speaker to maximize sound
quality and also to prevent the cable being
pulled out and the phone falling. The base will also have feet which allow the product to stand, stopping the wood from being marked and getting
scratched. The wooden base has a vanished finish. This makes the plywood smooth and slightly shinny, bring out the natural grain, thus adding
further aesthetics. The finish I will use will be a water based varnish. This means that I doesn't contain oils. This is more environmentally friendly as
there are less chemicals to pollute the earth and less oil extractions. This also means that you can wash the varnish off the brushes and down the
sink. Meaning the brushes aren't destroyed, reducing waste, and the chemicals won’t accumulate in the swage and water drains. It is also safer for
me as the chemicals are less harmful to the lungs.

Cutting list
Part Material Thickness Size (L x w (mm)) Color Quantity Price (Pounds)
Mould for vacuum
former (Base)
Modelling plasticine 35mm 173 x 155 N/A 0.5kg N/A as reused by
school
Mould for vacuum
former (Top)
Modelling plasticine 100mm 110 x 110 N/A 1kg N/A as reused by
school
Vacuum formed
shape
H.I.P.S 3mm 454 x 130 White 1 sheet £0.10
Base Plywood 5mm 500 x 500 N/A 1 sheet £1.32
Legs Acrylic Rod 10mm (Diameter) 20 L
30 L
Green Light
Gathering
2 x 20
2 x 30
£0.19
Legs Acrylic sheet 3mm 30 x 30 Green Light
Gathering
14 £0.38
Speaker component Metal 15mm 50 (big diameter)
43 (small diameter)
Black 2 £1.75
Ikea OLEBY lamp Polypropylene
casing
17mm 67 x 76 Black 1 £5.00
Speaker Circuit Metal 1mm 53 x 45 N/A 1 £1.75
HIPS legs Bubble rod 6mm 50 Bubble clear 4 £0.20
HIPS plate Polypropylene 7mm (radius ) 43.98 area
31.42
Black 1
2
£0.06
Stickers Vinyl n/a 70x200 Black 1 £0.06
These are the materials that will be needed to manufacture the product in the correct quantities with the
correct costs. In mass production the total price would reduce as it is cheaper to buy things in mass than
separately.
Total: £10.81

Evidence of CAD/ CAM
Computer aided design and manufacturing (CAD/CAM) is very important in industry to make quick, precise designs to be made, then manufactured and
produced in mass efficiently and effectively. However, my product is a one off, but with the use of CAD/CAM some sections of my design could be mass
produced, in large scale production making multiple copies of the exact product/design.
In my design I have used CAD/CAM to make the:
• Shape that goes around rod to make the feet of my product. This helped to get the shapes similar and match. This adds extra aseptic appeal making
the overall look of the product more attractive.
• Template for the plywood base, the shape will be exact with the correct dimensions.
• Layers on the base that support the phone, to get the exact same shape so the layers match perfectly.
• Plate that holds the speaker so that the measurements are precise and additional holes line up with the holes in the base. This was done by replicating
the shape and using a contour so the two separate parts ergonomically match.
• Caps for the rods to hid the rod ends when they stick up over the HIPS base and lamp plate. This covers them to make the finish look tidier. In addition,
adding extra aesthetic appeal and support to the structure of the product.
To reduce waste when manufacturing my product I made sure to nest the designs as close as possible. I also used others waste material that had large,
unscratched areas, therefore reusing others waste and reducing my own. This makes the product and manufacturing process more cost effective, also
having a more positive impact on the environment.
The CAD/CAM that I used was 2D design and the laser cutter witch accounts for size A2. In industry they would be using more technical CAD and much
bigger, efficient machines. In addition they would have larger facilities housing very large CAM machines such as injection and blow molders that help the
mass production of plastic bottles and other 3D prints. This type of machinery is much more high tech and expensive, therefore in schools they could not
have such machinery. The machinery and computer technology would be very expansive, however, it would be able to produce large quantities, in mass
production, at a fast working rate, thus having profit.

Plan of Making
Start
Gather modelling plasticine,
approximately 1.5kg worth
5min
Is that
enough?
Mould approximately 1kg into a
fluid base shape, apox. 175 x
155mm. To smooth put in oven
for 20 seconds to make soft.
90min
Is it smooth?
Are there
lumps?
Take the 0.5kg of remaining
plasticine. Mould into a dome
shape, approx.. 100mm thick
and 110mm radius.
90min
Is it smooth?
Are there
lumps?
Stick second mould of plasticine
in middle of first shape. Fill in
gaps between the two surfaces
using extra plasticine. Smooth
out.
60min
Are there any
visible gaps?
Release and begin to spoon the
plasticine out of mould, then with
a paper towel remove all excess.
15mins
Are there air
bubbles? Is
the plastic
smooth?
Pull down lever of vacuum
former and turn on suction. Allow
the plastic to form around
plasticine., rub around the edges
to smooth using gloves.
5 min
Is the plastic
springy? Is
mould in
centre of
vacuum
former base?
Place frozen mould on the
wooden base of vacuum former.
Allow the machine to heat up,
turning all settings on ‘FULL” and
time on “60 second’
5mins
Is the mould
rock solid?
Freeze full model for 24hours to
ensure rock solid structure.
24hours
Are there still
bits of
plasticine in
the mould?
Trim around edges using jig saw,
wear glasses. Leave a 10mm
border.
5min
Is there a
10mm border
around
shape?
Sand edges using wet carbon
paper to make smooth.
10-15min
Are the edges
smooth? Are
there any lines
of marks?
Using template mark out hole
for speaker with black
permanent marker. Begin to drill
large hole using 9mm drill bit in
middle of hole. Use dremel to
sand out hole up to the inside
marker line.
45min
Does the
speaker fit
comfortably?
Are the edges
up to the line?
Are they
smooth?
Use the belt sander to take of
extra wood and lines, then use
dry carbon paper to smooth.
20mins
Is the cut
shape the
same as the
template?
Using template, trace the shape
of the base on thick plywood. Cut
out shape using jigsaw.
20min
Is the hole
smooth and
even?
Using wet carbon paper wrapped
around the circle file, file the
inside of the hole.
10min
Open 2D design an design rings
shape for the feet of base. Turn
on laser cutter and cut 3mm
acrylic using 5.2% speed and
100% power. Big feet cut on
green and small on black.
45mins
Did they all
cut? Are they
the right size?
Clean all acrylic shapes using
tissue and methylated sprits.
15min
Are all marks
gone?
Glue black on bottom then
alternate colours for 6 more.
Glue using liquid solvent cement.
Wear mask and use syringe.
30min
Are there any
gaps? Are
there any left?
Drill 4 holes in the bottom side of
the plywood base using the
10mm drill bit. Dill in 20mm.
Ensure 10mm from the edges.
Wear safety goggles and apron.
30min
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No

Plan of Making
Are the holes
accurately
placed? Did
the hole go all
the way
through?
Using water based interior
wood varnish (crystal clear
satin) and a clean paint brush,
apply four layers of varnish on
the top, sides and boom of the
plywood base. Leave for
30mins each coat and then
sand lightly using P100 carbon
paper.
(Throughout whole making
process) 240mins
Is the surface
smooth?
On laser cutter (5.2%speed and
100% power) cut out 2x base
and 4x lamp holder pieces
using 3mm light gathering green
acrylic. Take out of machine
and clean using a tissue and
methylated sprits.
60mins
Are there any
marks still
present? Do
they not fit?
Glue all the lamp parts together
and all the base parts together
using a siring and liquid solvent
cement. Wear a safety mask to
limit the inhalation of fumes.
30min
Do they
match?
Glue acrylic black and green feet
onto wooden base using araldite.
Wearing mask, Then leave to dry
foe 20hours.
10min
Does it all fit
tight?
Glue, using a syringe and liquid
solvent cement, 3 clear dowel
into holes in acrylic base. Glue
light holder on top of the dowel
and glue on black caps. Wear
mask.
30min
Are the ends
flat? Are they
smooth
without cut
marks?
Mark out acrylic dowel. Cut out
4x 5.5mm D acrylic bubble rod
and 3x 6mm D transparent to
correct sizes using a JR hack
saw. The sand using wet carbon
paper.
30min
Is it fry? Is it in
the correct
place?
Glue the LG acrylic base to ply
wood basing using araldite.
Wear mask to protect from
fumes. Leave to dry fir 24 hours.
10min
Re they solid
in place? Are
they flat?
On laser cutter cut a 7mm radius
circle and 2x 5mm radius circles
made from black polypropylene.
Glue one smaller circles on both
sides using araldite with the
shiny ide facing up..
30min
Are they
circles flat and
in the centre?
Cut , using a JR hack saw, a half
lap joint in 3 pieces of clear
acrylic rod. Then, using a coping
saw, cut a 1mm slit on the other
side running half way through.
30min
Are the slits
straight? Do
they go half
way?
Sand using wet carbon paper
removing any cut line.
10min
Check if there
are any cart
marks? Does
it look tidy?
Is the solder
neat and flat?
Solder the speaker circuit fully,
then connect to speaker and
wires for jack port. Feed circuit
board through then, using
araldite glue speakers into holes
then place circuit board on plate.
1300min
Are the rods
strait? Are
they glued
tight?
Glue the 4 caps over the holes
in the black casing using liquid
solvent cement, ensure there is
still access to holes. Then glue
the bubble rod dowel into the
cap through the casing, using
liquid solvent cement. Hold to
dry.
25min
Are the flat?
Are they
strong?
Flip the black HIPS casing over
on a soft surface and, using
araldite, glue on the joints
opposite to the main bump.
Hole for 5 minutes to stop
sliding then leave to dry for 24
hours. Slot in the polypropylene
plate to ensure that its straight,
15mins
Cut out 2x speaker mesh with 5
rings for each. Glue all the
pieces together using liquid
solvent cement..
30min
Are all the
pieces
aligned?
On the belt sander sand off
acrylic to make a curve the same
as the black casing. Wear safety
goggles and apron
10min
Is the curve on
the mesh
complementar
y to the black
casing?
Glue the complementary mesh
over the speaker on the HIPS
using araldite. Hole both for
5mins then leave to dry for 24
hours.
10mins
Do they fit
comfortably?
Does the
speaker work
with the mesh
on?
Clean all plastic using meth's
then test by putting the casing
dowel into holes in the LG base,
turn on the speaker and lamp.
10mimn
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Yes
Yes
Yes
Yes
Yes
Does
everything fit?
Is it functional/
No
Yes
End

Manufacturing Diary
These images show the processes of manufacturing my design. This is done to show that the correct procedures have been take ensuing safety and accuracy.
Moulded this shape by hand out of modelling
plasticine. Originally the base was bigger
however after checking if it fit in the vacuum
former, for the second time, the size had to be
adjusted smaller. I then warmed up my hands
and rubbed the plasticine in order to eliminate
any bumps, fingerprints or dents in the clay. It
was then left in the freezer for 24 hours to
make hard. This made it smooth and ready to
vacuum form.
The shape was vacuum formed using
3mm HIPS. The setting were all full and
the time was set to 60 seconds. This
was long enough to heat the HIPS to
make it ready to bend over the mould.
This went well as the plastic did not
crack or pop in anyplace. It was also
relatively easy to get the mould out.
This was done using a spoon and
scooping all the plasticine out.
The next step was make 2 holes for the speaker. To do this initially I used a 45mm forcenibit. To
avoid scratching and moving of the casing I packed plasticine under the speaker shape to hold it in
place. When drilling I encountered some problems. I had left some plasticine in the top of the mould,
thus the forcenibit kept sliding, Their was also a very high chance of cracking. To avoid this I had to
use a different process. Sand the hole with the dremel was a lot more accurate. I made a template
of the speaker using gray board, and with black permanent marked traced around d the hole. When
using the dremel I went to the inside of the line. This made an accurate hole and when testing it the
speaker fit perfectly. This change of method was more efficient and effectives, completely
eradicating any problems that could have occurred when using the forcenibit. However, there was a
high risk of the dremel slipping and scratching the work. This was avoid with concentration and
accuracy when holding it.
A card template was cut on the laser cutter to trace around on the
wood. This gives an accurate cutting mark. The wood was then cut
using the jigsaw. This is a less accurate way then cutting the wood
straight on the laser cutter. However due to the thickness and
material of the ply It could not be cut by the laser. In addition, the
wood would of caught fire causing more of safety hazard. The jigsaw
however gave a likely chance of splitting the wood, this could have
been disastrous as it would of made the base look very mess and
bad, meaning I would have to cut out the ply wood again. This would
be time consuming and wasteful. When the saw blade goes up and
down it begins to spit the layers. To avoid this I went slow and
accurately along the line. To finish I used the belt sander to sand the
edges and glass then carbon paper to sand the flat surfaces. This
made the wood smooth and ready to varnish, without the lumps and
bums which would ruin the overall finish by not having an even
surface and possibly splintering under the varnish witch would set
then look very bad.
I drilled 4 holes into the base
using 10mm drill bit. I wanted
to make sure that the light
gathering feet were still in
view even when under the
base, therefore making sure
the holes were only 10mm in
from the edges. The rod only
goes in 20mm into the base
so I used the nut and bolts to
stop the pillar drill bit going
any deeper into my work. This
is so the feet don’t stick up the
end to be visible. This would
make the product less
aesthetically pleasing also
lessening its strength.
Every 30-60 minuets I applied a coat of wood varnish. I always wore a mask. This
limits the amount of fumes I breath in, making it safer to use the varnish. I applied 4
coats on the side, bottom and top. Between each coat, using grade P100 carbon
paper, I lightly sanded the surfaces. This removes all droplets of varnish and bumps
in the work, evening the surface, enhancing the overall quality of the base. A
problem that occurred was that dust from around the room began to get into the
layers of varnish. To stop this from happening I had top move away from areas of
dust, alternatively, when I sanded between coasts I moved away from the
varnishing area. The varnished used is water based, this means that there isn't oil
in it. This is better for the environment and better for me, there are less fumes
present to destroy your lungs and les chemicals to pollute the earth. In addition, the
water based varnish is better for the facilities and other equipment. When using
paint brush's, oil based substances cant be removed. Thus, the brush is destroyed
and must be thrown out. In addition the varnish cant be washed down the sink.
However, with the water based varnish the burses can be cleaned and reused,
reducing waste, being more environmentally friendly, also the varnish can be
washed down the sink with less chemicals present top pollute the water systems,
meaning less harmful impacts on the environment.

Manufacturing Diary
Here I drilled 4 holes to fit the rods onto
the rim of the black plastic. The holes
had to be marked out so that they would
match up to the acrylic base so that the
rod could run through, not the wood. The
drill bit used 5.5mm this ensured a tight
fit. This drilling was successful, however
the holes are very close to the edge of
the HIPS, this means that there is a high
chance of the HPS cracking when
drilling through and inserting the rod. To
try and prevent this everything had to be
done slowly.
On the laser cutter 4 identical pieces of light gathering green acrylic were cut out.
These sheets had a hole for the phone with a hole for end of the jack port cable and 3
small holes, ?mm, for dowel to go through to hold the speaker. The four base cleaned
using soft tissue and meth, then they were glued together using liquid solvent cement.
When gluing I always wear a mask. This limits the amount of fumes that were able to
accumulate in much lungs making it safer for me to work. When gluing together the
dowel was put in the holes. This ensures the holes and shape was line up accurately.
This process was successful overall, however, due to the acrylics transparency you
can see the glue marks. This is a feature that can not be prevented and is just a part
of the process, It does make the work look less professional though. On the laser
cutter 1 full plate and 3 rim plates were cut on 3mm green light gathering acrylic,
ergonomically shaped to hold the lamp. These were then all cleaned and glued
together that same way as the base acrylic. This was successful apart from the glue
stains, again which cant be prevented. I also noticed later that there was too much
space between the top of the holder and the top of the lamp, therefore I created
another piece of rim plating to glue on to the rest to extend the height.
When the dowel, acrylic bubble rod, is attached to black
HIPS the rods top will be visible. This will look less
aseptically pleasing, thus I created 2 rings and a top plate
to cover the top of the bubble rod. This will ensure a high
quality finish and allow the product to look more
professional with higher completion in the byers market.
The rings were 3mm LG green acrylic and the plates were
3mm black. There were two green rings then the black
plate. This layering of different colors give a splits of the
same colors so that not all the black is onto of each other.
This adds further aesthetic appeal as with the black on the
top almost makes that part of the product is complete, as it
matches the solid black top of the speaker holder.
These are the feet for under the wooden base. These
were made, on the laser cutter, using 3mm LG green
and black acrylic. To make the feet look more funky,
unique and creative, I layered the colors, sizes and
shapes. Initially I planed on using bubble rod, however I
decided not to as when the pieces were glued on you
cant even see the bubble, thus the use of more
interesting looking dowel would have been a waste.
Once I had cleaned the pieces using meth I then got the
right order then used a syringe and liquid solvent cement
to glue it altogether. On the bottom there needs to be a
full foot shape, without a hole, to cover and protect the
end of the rod. This piece had to go back into the later
cutter and get the hole engraved as it did not place flat
as the rod began to stick out. However, after this
everything was successful.
Here I cut out the holes for the to
go through into the acrylic to hold
the HIPS shape. There was a
high possibility of the acrylic
cracking so when drilling I had to
go very slowly and hold down the
base firm. One problem was that
when the drill went all the way in
the wood, dust and shavings
accumulated in the layers. To
solve this problem I had to
carefully split the layers and blow
the dust out. When the fog dried,
I could then glue them back
together.
Using araldite, which glues wood to wood, I glued
my acrylic feet into my plywood base. To glue I
used a mixture of half and half mixed using waste
strip of acrylic plastic to reduce impact on the
environment and enhance quality when applied.
The base was turned upside down for easy access
to holes, reducing mess. Using a large sized blob
of glue on the end of the rod, the legs were glued
in place. I didn’t apply pressure as the glue would
squeeze out onto the wood and layers of plastic
on feet. This would damage the aesthetic appeal. I
lightly pressed down to get the dowel in. The
araldite has a 5 min touch dry then 24hour set dry.
After 5 minuets I tuned it over to stand on its feet.
This ensures that when set the feet are straight
and flat.
I cleaned the all the LG acrylic base pieces
with meth's to take of any marks. Then
aligned them ready to glue using liquid
solvent cement. I used a syringe as its
small, reducing mess, wore a make to
protect my lungs from the fumes, and
always tut the cap on tight to reduce others
inhalation of fumes. Once they were all
glued I put the dowel in to ensure it was all
straight. This was then left to set. I then
lined up the acrylic base in the middle of
the ply wood base. I applied araldite onto
the acrylic and stuck it down to the wood.
Making sure it didn't’t slide around I held it.
This then was left for 24 hours to dry.

Manufacturing Diary
I cut out 3x 30mm clear acrylic rods using a JR hack saw,
then marked out and cut a half lap joint on one end and a
1mm slit on the other using a coping saw. Using P1000 wet
carbon paper I smoothed both ends of the rod in a circular
motion to sand off any cutting marks and make aesthetically
pleasing. I then used wet carbon paper wrapped around a
square file to sand the half lap joint, filing along the cutting
grain to smooth out all the marks to make the work more
aesthetically pleasing. This also made the lap joint more
strait, ready to glue to the HIPS using araldite.
The slits were sanded using wet P1000 carbon paper to ensure that the 1mm
polypropylene would fit. The 1mm slits cut for the polypropylene had to be cut
straight next to the joint. However, one of the slits cut was slightly on a diagonal.
This meant that when gluing it needed extra glue so it could be angles to make the
slit flat so the polypropylene would fit. Whilst the glue dried the polypropylene plate
was inserted into the slits. This meant that the finish would look a bit rubber, but
this could add extra appeal. The extra glue meant that the joints glued on correctly
ensuing the plate would slide in and out with ease. The joints were glued flat onto
the inside of the HIPS casing. Araldite was used as it ensure strength this means
that it can support the weight of the speaker components, (Circuit board and
battery). The rods had to be held in place for 5 minutes to prevent slipping out of
place. In addition the black casing had to be held on my lap in a cloth to prevent
damage such as being scratched. Moreover, when gluing the joints onto the HIPS I
put in the polypropylene to make sure that the slits were level.
I soldered the circuit board together using solder and
a soldering iron with the assistance of various pliers
and cutters. I ensued that all the excess solder and
wire was cut off to make the bottom of the circuit
board flat so that it fit into the black casing. To make
sure that the fumes from the solder were no inhaled
too much I opened some windows and blew off the
fumes every 4 solders. The solder connects the
components to a copper track which completes the
circuit. The components include a switch and jack
port, these 2 main features are essential for the
speaker system to work as they allow the sound to
travel from the phone and the speaker system to turn
on and off.
I then glued the dowel into the
acrylic base. This dowel allows the
black HIPS to stand over the base.
There was one very poignant mark
on one of the rods, this could not be
shown, therefore it was glued down
into the base, so only the clean end
was showing. Similarly, to the last
step I had to make sure that all the
gaps were filled but letting in as
much glue as possible until no more
was pushed in.
Once the acrylic base was glued to the plywood I could then glue in
the clear rocs for the lamp stand. I glued these in using liquid solvent
cement. Separately, I glued the black circular caps onto onto the
holder using liquid solvent cement. This meant that when I glued the
holder to the dowel the dowel wouldn't’t stick out so that the caps
could not would be stopped the lamp holder wouldn't’t fall all the way
through. I then glued both parts together; the lamp holder to the dowel
rod using liquid solvent cement. To ensure this was strong enough I
had to make sure I filled up all the holes until the glue no longer went
in.
I decided to add stickers to
the base, this adds an
extra appeal and covers/
draw attention away from
the liquid solvent cement
marks in between the light
gathering acrylic base
layers. The stickers were
cut on the vinyl plotter
using black vinyl. I then
used transfer tape to take
the stickers from the
material to the acrylic.

Manufacturing Diary
I glued the speakers in one at a time so that I could hold
one in place to stop sliding and let it set for 5 minutes. I
glued one in when the wires were connected to the
circuit, but I glued the other without being connected.
This meant when they were glued and set I could turn
the casing over and connect the wires. A dab of glue
was placed at the top and bottom of the speakers then
they were held in place. I then put the plate in, so the
circuit was closer to the speakers, this meant the wires
weren't being pulled. This reduces damage to the
speaker. Whilst gluing I had to avoid getting any glue on
the front of the speaker as this could have caused the
sound from the speaker to muffle, reducing the overall
quality of its function.
This is the overall product. The black casing is
not glued down to the base, it rests on top of
the rod so the battery can be changed easily.
The lamp faces down in the lamp holder and
has a motion sensor to turn on. The speaker
turns on by the switch in the circuit board that is
accessible when the HIPS is lifted and the
polypropylene table slides out. To finish,
everything is dusted then all the plastic is
cleaned using meth's and a tissue, cleaned
away from any dusty areas. This takes off any
remaining marks and fingerprints that have
been left on the work.
I glued caps over the holes for the bubble
rod that will hold the HIPS up. I used liquid
solvent cement. Some of the holes drilled
were on a curve or slant, this effected the
ability to glue the caps flat making them
strong enough. To fix this I just had to use
extra glue to fill the gaps so that they were
strong enough to support the speaker.
These caps will not be glued onto the dowel
as this HIPS needs to be free so the top can
lift off to change the batteries of the speaker
and light. Being able to take the top off also
means I can easily access the on and off
switch for the speaker.
I then glued 5 layers of black acrylic rings together using liquid
solvent cement. The 6th layer was the mesh design. The mesh is
designed as circles to match the distorted and not regular or
streamline features in my design. This adds further appeal to the
product. The rings and mesh were cut and engraved on the laser
cutter, using speed as 5.2% and power at 100%. The whole
mesh then had to contour the black casing, this meant that it
needed to be curved. I used the belt sander to curve the mesh.
The vibrations of the sander began to split the layers, thus more
glue was needed to withstand the force. After I sanded the mesh
down to as close a contour it would get, I re-glued the layers,
then sanded the edges using P1000 wet and dry. This made the
edges smoother ready to glue onto the HIPS.
Some of the liquid solvent cement poured through
to the front of the mesh. This left white stains on
the product. To cover this I wanted to add an
extra ring on the front. I tested both colours , LG
green and black, then found that this
arrangement looked most aesthetically pleasing,
as it could be seen to portray a camera lens or a
popular brand of speakers from ‘Beats’. So I
glued the light gather green acrylic rim to the
mesh, then the black rim on top of that using
liquid solvent cement. I was carful not to let any
glue onto the visible surface of the mesh.
I glued the mesh to the HIPS casing over the speaker using araldite. A
large glob was used to ensure the stick was strong and all the gaps
were filled. There were holes between the mesh and HIPS as the
contour could not be exact, thus more glue was needed to fill these,
this did however leave a rubber finish, but the gaps looked sealed and
complete. In addition, the glue was applied around the rim and the
inside of the mesh. This made sure that the glue would not only stick to
the HIPS but also to the rim of the speaker. This made the product
stronger and more durable. Both mesh were glued at the same time as
it was easier to hold both mesh to get an accurate alignment. They had
to be held for 5 minutes to prevent sliding out of place, then left for 24
hours to set fully.

Evaluation – Final Images
The evaluation investigates the positives and negatives of a product, drawing upon the success of the product and any modifications that could be made next time to improve it.
This is my finished product, overall I am please with the outcome; the product met most of the requirements of my design specification and brief, the product is functional and it
is still very similar to the development design. Thus showing I followed my development planning rigorously.

Design Specification Have I met the
requirements?
Comments
Appeal to a Target market of ages 8 years and onwards; both men and women. This is because there is a large
percentage of people who listen to music, however if younger than 8 they may not be as capable to use this technology
without harming themselves and or others. To ensure this target market is portrayed in the product the design must be
kept simple yet unique and mature.
✔ The target market is still 8+, however the product is more suited to the younger part of the
spectrum. This is different then initially intended as the shape is complex and more childlike,
opposed to my initial idea of simple and sleek. However, majority liked the more child like design
and I believe that the plain, simple colours create a balance.
Be suitable for any Religion and race, and will not contain any offence signs (i.e.. R18 material or the swastika) that
could offend a particular facet of society. Thus making the product open to any religious beliefs, respecting each
individuals values. To do this the product will be kept simple and mature.
✔ This target has been met as there are no offensive signs, stickers or sayings that could be offensive
to any particular religion or race.
Meet the demands of the Purpose; to project a good quality sound and light, in order for the consumer to read in the
dark, and listen to music anywhere, as it will be portable. To ensure this the product must be light in weight, able to
withstand different weather conditions and easy to use.
✔ The product meets the specification as it is functional, however the ability to be portable has been
compromised. The design was modified to stay in one place, for example as small table, as it would
be too heavy to move around, and the plate would not support lots of movement.
Suit the Environment that the system will; which is not limited. As it is portable and due to its purpose it should be able
to be place on a bedside table and or counter. However, also needs the stability to hold its self up on the floor, or other
places on the ground, whether it is inside or out.
✔ This suits the environment, although a little larger than expected. A base was added in order to
protect the speaker and hold the light, the product became heavy. The environment however can
still be in or out side, and placed in a number of places without being too unobtrusive.
Be limited in Size in relation to its environment, and the conservation of the environment. The product must be small
enough to fit on a small table, or equivalent space on the floor. In addition the product cant be too big as it needs to be
able to move around as a portable devise.
✔ This has successfully met the specification. The product can be place in and out side, on a bench or
table. The dimensions do not effect its ability to be portable.
Ensure that it is light in Weight. This is related to the purpose and target market. Due to the fact it should be a portable
speaker system with the age limited to 8 years and above, the weight of the product must be kept small so that it is easy
to carry around and move. To do this the materials used must be somewhat light (i.e. MDF, acrylic).
✔ The weight of the product is a little heavier than expected, however it is still easy to carry around
from desk to desk. I used plywood. This meant that the timber made the product heavier. However, I
did use acrylic keeping most of the product lightweight. I would either use thinner plywood or MDF
if manufactured again.
Establish good Durability of the, as the product should be expected to last around 3-4 years. The product must be
durable as it may be found in spaces where its knocked around or placed on a rough surface, thus preventing damage.
To make the product durable I will use plastics that are strong, however not brittle, and resistant to wear. I will also use
woods coated with a finish to ensure quality and prevent damage and wear.
✔ This has been successful. Lots of the products is glued using araldite, witch is a very strong glue.
The wood has been varnished, this makes it more resistant to corrosion and water damage. This
means the product will last for a long time, thus increasing durability.
Have Aesthetics limited to plain and simplistic patterns, however bold colors, as its suited for such a wide range of
people, it needs to be appropriate for everyone. In addition, it needs to suit any environment its in. The look should be
simple but effective as the product needs to take into account maturity and offence when put on the market to compete.
✔/✘ The patterns on the design are simple and the colour scheme is bold and simple, using only black,
green and wood. The design however is more complex. Thus, not fully meeting this target. I would
change the external colour of the shell or add stickers so it can be seen and appreciated when in the
dark.
Be made out of Materials that have a range of functions. Such as, lightweight, waterproof, fireproof and strong. This will
contribute to the products durability and use. To ensure this the product will be made out of wood, with a finish or
varnish, and a plastic succumbs to these properties.
✔ The plastics chosen are all light weight and water resistant. However they are brittle. The wood has
been varnished making it water resistant. Thus, meeting the criteria.
Acquire a relatively cheap Cost that is affordable for the range of the large consumer market. Therefore, the materials
must additionally be cheap. This will allow the product to compete on the market and be made easily in industry on a
large scale without being too costly.
✔ The cost is affordable. It is not to high as I managed to reduce waste when possible, however, the
quantity of material, ie. Acrylic, used was large as much of the plastic had to be layered. Overall, the
price was not too high. Thus meeting this demand.
Take into account Environmental issues. For example, the materials used must have the ability to be reused and
recycled to form another product. Moreover, the waste of the materials must be minimal. Furthermore, the materials
chosen must be the most sustainable materials that are available. To ensure this the product will be made out of
thermoplastics and sustainable wood. Such as, but not limited to; Acrylic, H.I.P.S, MDF and Beech wood.
✔ This target has been met as the finishes used were water based, thus being more environmentally
friendly. I also used thermoplastics and ply wood. Both materials are sustainable and have an
environmentally friendly life cycle.
Be suitable for Mass Production in a factory or workshop., however the product that I am making is a one off prototype.
Therefore, the product must include elements of CAD/CAM to show that its suited for this Manufacturing process.
These elements will be incorporated by using the 2D design, the laser cutter and vinyl plotter; using materials such as
acrylic, vinyl and polypropylene.
✔ I used CAD/CAM to product stickers, template and cut out acrylic for the base and other parts of the
product. This can be used in mass production as an efficient way of producing identical product. My
product used CAD/CAM, therefore it is suitable for mass production.
Evaluation against design specification

Speaker / Lamp

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