final project

DESK LAMP REDESIGN
1.INTRODUCTION:
1.1 Problem Identification:
There are many people specially students who have only one desk lamp in their dorm.
They use most of the time because we know how the student’s life is. How about if the
student needs a lamp that can light all the room while he is not in the desk studying
(normally during weekends or at the time of sleep when they need to chill a little bit in
the room). So, the idea of doing a multipurpose lamp came from that issue. Since there is
not such a multipurpose lamp available in stores, I decide to create one of this. This lamp
is created to all the public, but is mainly focused to people who use a desk and a room
lamp (students).
1.2 Product Description:
You know what's surprising about regular lamps? They are only of one class. They either
are desk lamp or dorm lamp. What fun is that kind of lamps? We'll answer that: NO FUN
AT ALL. You know what is fun? Using the multipurpose lamp to either convert it into
desks lamp or room lamp.
The lamp is ideal for use in a home a teen's bedroom or a dorm room. Since it can either
transform in desk lamp or room lamp. I will describe the benefits of each.
When is in desk lamp mode it adds a modern touch to any space. The swinging arm
design allows you to direct light wherever you need it. It is a simple to help you work or
study easily and conveniently.
When it is transformed into room lamp mode it light up your room or bedroom. It has a
white translucent shade that's positioned upward to illuminate a large area. It has a strong

metal construction for durability, with a steel finish. It has a 3-way rotary switch for easy
use. This steel floor lamp can be quickly assembled without any tools from its desk lamp
mode or vice versa.
Desk Lamp

The customer can transform in either one of these two by making some adjustments to
the lamp (rotating the upper arm part and by extending the two tubes up to the desired
position).
The product contains an upper part that can be moved to the desired position since it
contains a knuckle joint.
Before and after tubes
These systems of telescoping tubes have the function of give longer height when the
customer decides. The customer can have longer height just by unlocking the quick
release clamp that comes with each tube. The new lamps’ height will be three times taller
than the desk lamp.

(Two different lampshades)
The new lamp contains two different lampshades (one for the desk lamp and one for the
room lamp). They are easy to take out and change it according to the situation. To take
one lampshade out, it just requires to turn around few times and done.
The final product is a lamp that can be converted into a desk lamp or into a room lamp as
the customer’s desires.
It is important to say that even tough this lamp contain many parts because it is two in
one, it is not heavy. The fact that it is not heavy doesn’t mean it is not durable or it
doesn’t have quality. It is made from steel a durable and strong material. So you just
have to worry about taking the most advantage of it.

1.3 Product Comparison:
Product name Picture Features Price
Steel Floor Lamp
Room Essentials®
-It has a white translucent
shade that's positioned
upward to illuminate a large
area.
-This lamp accepts either a
150-watt incandescent bulb
or a 26-watt CFL bulb.
- This Room Essentials light
lends an upscale look to your
home décor.
-It has a 3-way rotary switch
for easy use. This steel floor
lamp can be quickly
assembled without any tools.
42.99$
Swing Arm Desk
Lamp
Mainstays
-It is ideal for use in a home
office, a teen's bedroom or a dorm
room.
-Adds a modern touch to any
space.
-The swinging arm design allows
you to direct light wherever you
need it. The
22.97$

1.4 Advantages and disadvantages:
Picture Advantages Disadvantages
-It lights a room evenly
-It has a large arm,
meaning that it will
provide the most evenly
illumination in the room.
- Useless at the time of
trying to light a specific
space such an environment
of a desk). Specially, for
people who study during
the night.
-Since it has that long arm,
it is difficult to move it
around the house and
almost impossible to put it
in the glove compartment
of your car(when you are
moving from apartment)
- Perfect to give the
maximum illumination to
a certain environment. It
will illuminate just the
space you need when
you are in the desk using
your computer or
studying (students and
businessman)
- Not useful at the time of
trying to light your entire
room because you will find
very illuminated in the
desk area and very dark in
the rest of the room.
1.5 DesignAnalysis:
The new lamp design contains as many sophisticated and complex parts as possible, as
the project required.

There were many options for the new lamp design but after many challenges and
investigation a final design came out.
Some designs options that I had are named next for the different parts:
Different kind of designs for the different parts:
System of telescopic tubes:
Option 1. System of tubes with friction locking
This system of poles is very light and it works based on a friction joint. This is very
interesting because it works based on friction. Once you elongate enough, they will
automatically lock themselves. The disadvantages of this system are that when you
unlock (by pressing where the two poles meet), it will collapse very quickly and can
cause an accident, because lamp components above it can hit the person.
Option 2. System of tubes using clamps as a locking system
The concept of this system of tubes is very simple. The customer can elongate the tubes
and adjusted with the clamps that were designed to fit with them. It is very safe because
the clamps have a secure locking system. For the final design option number 2 was
chosen, mainly for the advantages. 3 tubes of 1 foot and different diameter were chosen.
0.028” thickness wall tubes were chosen. It was made as thin as possible because for
price purposes and the load they will carry which is not more than some pounds.

Each tube goes inside the other and they can be taken out by pulling them. This kind of
system is also called telescopic tubes system.
Clamps (to lock the tubes)
Option 1:
There was not a predesign clamp model for the requirements that the final design was
looking for. After a research about the right clamp to lock the tubes, it was decided to
create a unique clamp for this design. This unique clamp will do two important jobs. Half
of the clamp will go stuck with a tube and the other half will do the job of locking the
other tube beneath.
Joint in the upper arm
Option 1. Ball and socket joint.

This model was put into consideration for the main joint in the design. But it wasn’t good
for the required purposes, because the left part can move in all directions and it cannot
make 90 angle with the other part, which was desired. The final design required an arm
that can be moved between 90 and 0 degrees in one plane but not all directions. This is
why this design was discarded.
Option 2. Knuckle joint.
This model was chosen for the final design. There were many knuckle join models and
designs. After taking some ideas from other models and putting the desired
measurements the above design came out. This design moves in one plane and it can be
moved in such way that it will be normal with the main tube (in desk lamp mode) and
straight (in room lamp mode) and it was perfect for the project because it is simple,
which is the purpose of this project. This design was chosen also because it is safe, once

it is moved from horizontal position to the vertical position it stays there and it requires a
certain type of force to move it back to horizontal position.
For the rest of the parts there weren’t really other options to pick up from, these were like
the default parts. They were designed either thinking on the main parts named above
(tubes, clamps, joints) or stability, resistance and simplicity.
Load Base
This load has the function to stabilize the lamp. This base has the exact load to prevent
the lamp to fall. After many calculations and taking in consideration all the forces that the
lamps parts will create, it was decided to put a 10-pound force in this base.
Cover base

It was decided to put a metal part cover to the load base. This cover base has the function
to cover the load base, which doesn’t have a good appearance. It was also added because
of design purposes and elegance.
Washers, nuts, connectors
There are a lot of these parts in the final design. These were chosen having in mind the
main parts and depending the location and the type of joints.
2. WORKING DRAWINGS:
2.1 Assembly drawings:

2.2 Bill of material:
Part number Part name Quantity
1 Lamp Shade 1 1
2 Lamp Shade 2 1
3 Flexible Locknut 1
4 Switch 1
5 Incandescent Light Bulb 1
6 Knuckle Joint 1
7 9/16” Quick Release Clamp 1
8 ½” Quick Release Clamp 1
9 7/16” OD Tube (1 foot long) 1
10 ½” OD Tube (1 foot long) 1

11 9/16” OD Tube (1 foot long) 1
12 7/16” OD Tube (1/4 foot long) 1
13 Connector 1
14 Outer Base 1
15 Flat Washer 1
16 Load Base 1
17 External-tooth Lock Washer 1
18 Thin Hex Nut 1
19 Light Bulb Adapter 1
20 Power Cord 1
21 Tube Connector 1
22 Light Bulb Adapter Cover 1
2.3 PART DRAWINGS:

3. MATERIALS SELECTION AND MANUFACTURING PROCESSSES:
For Custom Parts:
Part # Snapshot Material Manufacturing Process Reason
1 Stainless
Steel
Rolling. Stainless steel undergoes
rolling until to get a very thin layer
of it.
After that, a worker cut it and gets
the exact dimensions. The last step
is to weld all that pieces together.
1. 1. Have a high resistance to corrosion.
2. 2. Ease of fabrication because it is fabricated
readily.
3. Aesthetic appeal, because it is easily
and simply maintained resulting in a
high quality, pleasing appearance.
3.
2 Glass Molds. Melted glass is put it into
the molds to take form of the
container. This process was chosen
because the figure to is simple. It
didn’t require much complex
processes.
1. Glass was chosen for this lampshade
because it was required one material that light
can pass through it and illuminate a big space.
Therefore, glass was perfect for this piece.
3 Plastic Plastic Extrusions. Pellets are
heated and mechanically mixed
with the screw. It is a hot process.
Melted plastic is forced through a
small opening and cooled in air or
water.
1. Plastic was chosen for this critical part.
Because the component around this piece have
energy passing through, it was really
important to put a material insulator, such as
this, plastic.
2. The outer components of the lamp are made

This process was chosen because it
is the cheapest available among
many.
of stainless material, which are good passing
energy, that’s other reason why plastic was
chosen to prevent accidents. (Electroshocks)
4 Stainless
steel
Extruding. To make this little rod
the extruding process was chosen.
A round billet is placed in a
chamber and force through a die
opening.
A very long rod is get it then is cut
it in little pieces forming little rods.
Which was exactly what was
needed for this piece.
readily.
high quality, pleasing appearance
6 Stainless
steel
Extruding. To make all these rods
opening.
Then is made by hand to mold all
the pieces forming the different
figures.
1. Strength when it is heated to make very
high strength components.
2. Hygienic properties because, The
clean ability of stainless steel makes it
the first choice in most places.
3. Life cycle characteristics because,
Stainless steel is a durable, low
maintenance material and is often the
least expensive choice in a life cycle cost
comparison.
7,8 Stainless
steel/
plastic
Plastic extrusions. Pellets are
water.
many.
All the clamps’ components are made of
plastic, except the little rod. This is because:
1. Just the rod is made of stainless steel
because is where most of the stress will be
concentrated, and a strong material was
needed.
2. The rest of the components are made of
plastic, which is cheaperthan other materials.
3. Even tough it is plastic and cheaper doesn’t
mean it is not strong, it is strong enough to
hold the load, which will be acting on them.
9,10,
11,1
2
Stainless Extruding. To make the tubes the
extruding process was chosen. A
round billet is placed in a chamber
and force through a die opening by
a ram. It was chosen because it is
a cheap process.
readily.

water.
many.
1. Plastic was chosen for this critical part.
Because the component around this piece have
energy passing through, it was really
important to put a material insulator, such as
this, plastic.
2. The outer components of the lamp are made
of stainless material, which are good passing
energy, that’s other reason why plastic was
chosen to prevent accidents. (electroshocks)
14 Stainless Rolling. Stainless steel undergoes
rolling until to get a very thin layer
of it.
After that, a worker cut it and gets
the exact dimensions. The last step
is to weld all that pieces together.
1. Strength when it is heated to make very
high strength components.
2. Hygienic properties because, The
clean ability of stainless steel makes it
the first choice in most places.
3. Life cycle characteristics because,
Stainless steel is a durable, low
maintenance material and is often the
least expensive choice in a life cycle cost
comparison.
water.
many.
The function of this load is vital for the lamp’s
equilibrium, because it holds it still meaning
that it won’t fall. The load requirement for
this load was that it had to be heavy enough
such as 10 pounds in a area of 34in^3 and
plastic was chosen.
Plastic was chosen mainly for the cost, which
is cheap
21 Stainless
steel
Extruding. To make this little rod
opening.
readily.
10.

22 Plastic/
stainless
steel
Plastic Extrusions. Pellets are
water.
many.
This is a part composed of two different
materials:
1. The outer part is made of stainless steel
because for design purposes so it connects
with the rest of outer components which are
made of the same material.
2. The inner part is made of plastic. It is made
from plastic as it named above because this
part is in contact with the materials that
contain electricity, in other words it works as
an insulator.
For Buying Parts:
Part # Snapshot Manufacturer’s part number Where to buy
5 15115K72 Mcmaster.com

15 93852A113 Mcmaster.com
4.FINITE ELEMENT ANALYSIS:
INTRODUCTION:
An analysis of the one part of the lamp was analyzed with Creo simulate. The part chose
to be analyzed is the “tube connector”. This part connects the tubes with the lamp base.
After making calculation to all parts’ lamp, it was found out that this is the part that will

be supporting more stress in the whole structure. It was found out that the piece was
resisting magnitude force of 29 pounds. This magnitude was distributed in 20 pounds y
direction and 20 pound in the x direction. This little piece is very important, because in
case of falling some accidents can occur. If this piece for any instance brake, the lamp
will collapse. That’s why the importance of making an analysis to this piece. With the
results of this analysis some changes were made including changing the material and the
diameter.
ANALYSIS SETUP:
Once the piece was opened on Creo parametric the next steps were followed in order to
perform the analysis:
1. Displacement
Some constrains were collocated in one end of the piece. All the directions
were set fixed, because displacement doesn’t occur at the base.
2. Applying the loads
In the load menu concentrated load was chosen. This load was collocated 20
pound in the y-direction and 20 pound the x-direction.
3. Materials
Material was assigned to the piece. Since the whole piece is made of steel, this
material was assigned.
4. Setting up the analysis
In the pull down menu file> new static was chosen. This opened up the static
analysis definition dialog window. In this window a 5% convergence and a
maximum polynomial of order 9 was established.
After all the steps named above the next figured was obtained:

RESULTS
After looking the results in the graph and fringe models and realized that our
improvements the new piece was correct. Before trying with steel the process was run
with aluminum being the material. The aluminum didn’t resist this stress but with steel is
vice versa. The maximum stress, displacement and convergence didn’t pass the
allowable steel strength allowance. This steel piece got displaced a little bit and it is
under the range of the material.
5 COST ANALYSIS:
The cost analysis was made based on the next assumptions:
1. That a company, which has been doing lamps for many years, is in charged of
making the new lamp model. This means that they have all the necessary equipment and
personnel to make any kind of lamp.
2. That the only thing this company needs to produce this lamp model is the raw
material.
Thinking the 2 assumptions that were made, the next steps were proceeding.

Raw material was brought. Only three kinds of raw materials were used in this lamp
model (stainless steel, plastic and glass).
-The stainless steel material was brought at (www.metalsdepot.com) company, which
is a company that sells any kind of metals in any kind of shape. A bar of 1ft x 1ft x 1ft
was brought at 25.50$. Which means that each volume cube of material (inches) cost
25.50$/(1728in^3)= 1.47 $ per in^3.
-The plastic material was brought at (www.professionalplastics.com) company, which
is a company that sells any kind of plastic in any shapes. A square of 12in x 12in x 12in
was brought at $53.33. Which means that each volume cube material (inches) cost
$53.33/1728= 0.03$ per in^3
-The glass material was brought at (-The plastic material was brought at
(www.professionalplastics.com) company, which is a company that sells any kind of
glass in any shapes. A square of 12in x 12in x 1in was brought at $12. Which means that
each volume per cube material cost $12.00/144= 0.08$ per in^3
Cost of each part by material:
Material Quantity of material needed
(In^3)
Price of raw
material per unit
volume
($)
Total cost of raw material
For one lamp
($)
Stainless steel After a meticulous calculation and summing all
the parts that contain stainless steel, it was
concluded that approximately 13 in^3 was
needed for one lamp
The price of stainless
steel is approximately
around 1.47 $ per
in^3
19.11$
Plastic After a meticulous calculation and summing all
the parts that contain plastic, it was concluded
that approximately 38 in^3 was needed for one
lamp
The price of plastic is
approximately around
0.03$ per in^3
1.14$
Glass After a meticulous calculation and summing all
the parts that contain stainless steel, it was
concluded that approximately 10 in^3 was
The price of glass is
approximately around
0.08$ per in^3
0.80$

needed for one lamp
Total 21.05$
To this price it was required to add the expenses during all the product process and
stages. All the percentages were get by doing some research in cost analysis.
Labor Costs: 30%
Labor: 10% to manufacture parts using relatively simple manufacture techniques
$2.10
Maintenance Labor 5% for maintaining shop equipment $1.05
Manufacturing 8% for power/utilities and machines. $1.68
Overhead Costs 10% Shipping cost and storage costs would be slightly
expensive due to size. $2.10
Sales Commissions:
Wholesale Price 15% $3.15
Manufacturer’s profit is 10% of the wholesale price. $2.10
Commercial sellers will be able to buy the product for 5% of the
wholesale   price plus retail price.
$1.00
Retail Price:
Dealer’s Profit Margin 15% $3.15
Advertising Costs 3% $0.63
Store Expenses 7% $1.47

FINAL COST TO CUSTOMER = $39.48
This is a great price to pay because as it has been told many times this lamp is two in one.
Most of the lamps with these kinds of characteristics are much expensive. For example if
it is combined the price of a regular dorm lamp, which is $42.99, and the price of a
regular desk lamp, which is $22.97, they sum up to $65.96. This is a price that a person
would pay if he/she could buy two lamps for one apartment. On the other hand, there is
this new lamp offers two lamps in one for a convenient price, specially for students.

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