GCSE Product Design

CONTENT PAGEPART A- RESEARCH:
 GCSE PRODUCT DESIGN BRIEF (LAMPS) &
ACCESS FM
 MOOD BOARD & CLIENT PROFILE
 QUESTIONNAIRE
 PRODUCT ANALYSIS (1)
 PRODUCT ANALYSIS (2)
 MATERIAL & JOINTS ANALYSIS
 COMPONENT & MANUFACTURING ANALYSIS
 DISASSEMBLY OF AN EXISTING PRODUCT
 CONCLUSION BASED ON RESEARCH
 SPECIFICATION (DESIGN CRITERIA)/QUALITY
CONTROL CHECKS
PART B- DESIGN & DEVELOPMENT:
 INITIAL IDEAS (1)
 INITIAL IDEAS (2)
 EVALUATION OF THE SKETCHES
 DETAIL SKETCHES
 MODELING & MAKING A PROTOTYPE (1)
USING CAD/CAM
 MODELING & MAKING A PROTOTYPE (2)
 STRENGTHS AND WEAKNESSES OF THE
MODELS
 DEVELOPING MODEL & CLIENT OPINION
 DEVELOPMENT (INCLUDING MESS
DEVELOPMENT)
 FINAL DEVELOPMENT
 FINAL DESIGN & CLIENT OPINION
 ORTHOGRAPHIC DRAWING + EXPLODED VIEW
OF FINAL DESIGN
PART C- MAKING:
 MAKING (BODY)
 MAKING (BASE)
 ASSEMBLY & WIRING (ELECTRONICS)
 PROBLEM WHILE MAKING AND THEIR POSSIBLE
SOLUTION
PART D- TESTING & EVALUATIONS:
 CLIENT & GENERAL PUBLIC OVERVIEW
 CONCLUSION BASED ON SPECIFICATION
 EVALUATION
 MODIFICATIONS & MASS PRODUCTION

GCSE PRODUCT DESIGN BRIEF
(LAMPS) &
ACCESS FM
PROBLEM:
FIRST CLASS PASSENGERS HAVE
A LESS EXPOSURE TO LIGHT
ESPECIALLY AT NIGHT WHEN THE
CREW HAD SWITCHED OFF THE
LIGHTS IN THE AIRCRAFTS WHEN
TRAVELLING ABROAD.
DESIGN BRIEF:
I HAVE BEEN ASKED TO MAKE A
DESIGN OF A LAMP FOR AN
AIRCRAFT FIRST CLASS
PASSENGER, THOSE PASSENGER
WHO HAVE LESS EXPOSURE TO
LIGHT ESPECIALLY AT NIGHT,
PASSENGER MIGHT NEED TO
READ BOOKS, WATCH TELEVISION
OR DO SOME WORK, BUT DUE
LESS LIGHT THEY CAN`T OR THEY
MIGHT CAUSING THEM TO TAKE A
RISK OF LIFE. DUE TO LESS
EXPOSURE OF LIGHT PASSENGER
EYE SIGHT MIGHT BECOME WEEK
CAUSING HEADACHE, ILLNESS AND
OTHERS. THIS LAMP SHOULD
PRODUCE LIGHT WHICH WILL HELP
THE PASSENGER TO EXPERIENCE
A BETTER QUALITY AND STANDARD
OF TRAVELLING. IT HELPS THE
PASSENGER BUT IT WILL HELP THE
AIRLINE AS WELL. IT WILL HELP
Aesthetics:
• Attractive and eye-catching look.
• Smooth, soft and gentle touch.
• Well polished, well finished.
• Stable base.
• Imperturbable and Inspirational
shade.
• Simple.
• Fits the environment.
• White, Silver and Golden color
used.
• Curved and Irregular shape that
attracts the customer.Cost:
• Cost should be
suitable for the
customer.
• The cost will be only
of the material of the
product and the
manufacturing only
Client:
• My client would be anyone, it
would be around all ages, means
no age limits, does not matter
what he/she do, and does not
matter what he/she likes or
dislikes. The only thing matter is
the interest, my client would be
interested in buildings and
architecture because my lamp
express these themes.
Environment:
• Eco-friendly.
• Efficient bulbs or
lighting should be
used, causing less
heat loss.
• Use less material,
causing less
wastage.
Safety:
• Stable base.
• Sharp edges need to cut
down
• Glass should not be used,
because if glass fell it will
Size:
• Medium Sized.
• Not too big not too
small.
Sustainability:
• Plastic used
can be
recycled easily
which will safe
the
environment.
Materials and
Manufacturing
Techniques:
• Laser Cutting to cut
the shape with smooth
edges (CAM).
• 3D print to cut
complicated shapes
(CAM).
• 2D design to draw
shape on CAD
• Vacuum former to
module the plastics in
any shape (CAM).
• Sanding machine and
Files to remove all the
rough edges (CAM)
• Saws to cut wood or
plastics (CAM).
Function:
• Main function
is to give out
light.
Theme:
• Architectur
e
Before sketching,
developing and
manufacturing the
product, firstly, I
have to research.
So lets start
researching.

MOOD BOARD &
CLIENT PROFILE
CLIENT PROFILE:
The lamp will be sold to an airline company, a company with many
Customers and Clients. My client would be anyone, it would be around all
ages, means no age limits, does not matter what he/she do, and does not
matter what he/she likes or dislikes. The only thing matter is the interest,
my client would be interested in buildings and architecture because my

QUESTIONNAIR
E
Architecture
42%
Science and
Tchnology
29%
Modern
Lamps
8%
Cars 21%
Themes of LampsBlack/Sil…
Blue
Yellow
Mixture of Colors combination of RED, GREEN, WHITE AND
BLACK
Wooden
Purple
Green
COLOR OF THE LAMP
Lighting
LED
Energy Saving
Pendant Lights
Neon
Mains
(AC)
Battery
(DC)
AC or DC
Mains (AC)
Battery (DC)
I have been asking my Clients some Questions about lamps and taking
some of their valuable advices; Some of the Questions are:
• What aspects do you look for in a lamp?
• What shape do you prefer in your lamp?
• What theme do you prefer in your lamp?
• What color do you prefer in your lamp?
• What would be the lighting type of your lamp?
• Do you want Alternating Current (AC) or Direct Current (DC) ?
The results to these questions are given as follows.
Irregular
Curved
Rectangular
Triangular
Shape
Irregular Curved Rectangular Triangular
What do you look in
your Lamp?
Aesthetics Cost Size Safety Material

Aesthetics:
• It looks simple, eye
pleasing and attractive
because of its light
purple--blue color.
• It is classic, old fashioned
but with modern touch
which means that extra
and attractive things are
added on classic, old
fashioned touched lamp
such as the color ,
material etc… This
shows that it is mainly for
the aged people.
• It`s base is made out of
blue acrylic plastics, so
that it is stable. It starts
with a curved base and
then goes up straight to
join with the shade.
• The shade is made up of
purple shade heat resist
fabrics, so that it is safe
and will not catch fire.
Cost:
• It costs around AED 50-
100 so that it is affordable
for all classes and
families
• The cost will be only of
the material of the
product and the
manufacturing only.
Client:
• Mainly for all classical
and old aged people who
are modern and like
fashionEnvironment :
• Made from eco-friendly
plastic so that it will not
pollute the environment.
• Light efficient bulb is used
which uses less energy and
produces less heat, and
Safety:
• Shade is used to
protect overheating of
the lamp, this shade
allows the heat to
resist.
• Soft edges are there,
so that there is no
roughness and there
is a better quality in
the product.
• It is stable so the is
will not fall over.
Size/Dimensions
:
• Medium sized.
Sustainability:
• Plastic used can
be recycled
easily which will
safe the
environment.
Materials and
Manufacturing
Techniques:
• Fabric which is heat
resistant coated
this is because it
will resist the heat
and will not catch
fire and will not hurt
others
• A blue acrylic
plastic is used to
make a stable
base.
• Laser Cutter is
used to cut edges
of acrylic.
Aesthetics:
• It looks striking and eye
shocking because of its
beautiful and
architectural structure.
• It`s whole body is made
out of nitinol, it gives the
flexibility to the lamp.
• It`s base has a rounded
shape so that it is more
stable, because rounded
shaped have a large
surface area.
Cost:
• It costs around AED
75-100.
• The cost will be only
of the material of the
product and the
manufacturing only.
Client:
• Mainly for
young people
and student
aged around
14-25 who
study at night
Environment:
• Energy saver is
used, which
produces less heat
causing less energy
loss.
Safety::
• Glass for
protecting heat
energy to be
released out
• Stable rounded
base, so that lamp
will not fall
Size/Dimensions:
• Medium sized.
• 6.9 * 5.5 * 20.1
Sustainability:
• Nitinol is used can be
reused because nickel
has magnetic
properties and with
electro magnetism it
can be recycled which
will safe the
environment.
Materials and
Manufacturing
Techniques:
• Glass is used for
protecting the
heat loss
• Nitinol is used, it
gives the
flexibility to the
lamp and it’s a
shape memory
alloy.
• Vacuum former isFunction:
• Main function is to
produce light.
• For studying.
Aesthetics:
• It looks simple and
eye catching
because of its white
color .
• It will attract kids as
well as some adults
because of its jelly-
fish structured
shaped who likes
marine life organism.
• The body is made
white acrylic plastic
shaped as a jelly
structure which
looks eye pleasing.
Client:
• Mainly for kids
aged between
6-13 who like
marine life
organism.
Cost:
• It costs around
AED 75-100.
• The cost will be
only of the
material of the
product and the
manufacturing
only.
Environment:
• Made from eco-
friendly plastic so
that it will not pollute
the environment.
• Light efficient bulb is
used which uses
less energy and
produces less heat,
and save costs as
Safety:
• Unstable base,
so that the
lamp might fall
over. They
should add
another base
with a larger
surface area.
Size/Dimensions
:
• Medium Sized
• 7.5 * 5.6 * 10.8
Sustainability:
• Acrylic used can
be recycled
easily which will
safe the
environment.Materials and
Manufacturing
Techniques:
• LED light is used.
• Acrylic plastic is
used to make a
body of the lamp.
• Laser Cutter is
used to cut edges
of acrylic.
Function:
• Main
function is to
produce
light.
• Table Lamp
Function:
• Main function is
to produce light.
• Can be used by
kids easily.
PRODUCT ANALYSIS
(1)

PRODUCT ANALYSIS
(2)
Cost:
• It costs around
AED 100-150
only of the
material of the
product and the
manufacturing
only.
Client:
• Mainly for mature and
middle aged people
who aged around 30-
50 years who read
books at night.
Environment:
used which uses less
energy and produces
less heat, and save
costs as well.
Safety:
• Stable base.
• Soft edges are used, so
that there is no
roughness and there is
a better quality in the.
• LED light protection is
used which resists the
heat.
Size/Dimensions
:
• Large Sized
• 10.2 * 7.6* 200.5
Sustainability:
• Aluminium reacts
with oxygen to
make aluminium
oxide which is
good for thermal
conductivity, it
also have a high
strength.
Materials and
Manufacturing
Techniques:
• Aluminium metal is
used.
• LED light is used.
• Welding technique
(Argon gas is used
for Welding) is used
to stick the base
with the body.
Aesthetics:
• It looks modest
and eye grasping
because of its
silver-metal color .
• It also charms
the customer
because of its C-
shaped design.
• Its top part gives
it a curve which
engages the
customer.
Function:
to produce light
• To stand within
the base
Aesthetics:
• It looks unobtrusive
and sharp because of
it wooden color and
shape.
• Its body is made from
plywood , which is
strong, causing the
base to be strong as
well.Cost:
• It costs around AED
50-100 so that it is
affordable for all
classes and families
• The cost will be only of
the material of the
product and the
manufacturing only.
Client:
• Mainly for all
conventional people,
this lamp has no age
limits which means its
for all ages.
Environment:
• Energy saver is used,
which produces less
heat causing less
energy loss.
Safety:
• Stable base.
• Wire is wrapped
around the plastics,
because plastics
are good insulators,
it will not conduct
electricity
Size/Dimensio
ns:
• Medium sized.
• 16.7 * 6.0 *
7,.5
Sustainability:
• Wood is a natural,
renewable
product therefore
is does not
releases many
carbon dioxide
emission.
Materials and
Manufacturing
Techniques:
• Plywood is used,
cause its strong
• Energy saver is
used.
• Laser cutter is used
to cut the edges
smoothly.
• Tenon Saw is used
to cut the wood.
Function:
to produce light.
• To disparage light
out on the
wooden part.
• Can easily been
carried
Aesthetics:
• Looks simple,
attention-
grabbing and
gorgeous
because of its
pentagonal
shaped base
and it shade.
• Its fascinates
the client
because of its
golden white
color .
Cost:
• It costs around
AED 100-115
only of the
material of the
product and the
manufacturing
only.
Client:
• Mainly for all
conventional
people, this lamp
has no age limits
which means its for
all ages.
Environment:
• Made from eco-
friendly plastic so
that it will not pollute
the environment.
used which uses
less energy and
produces less heat,
and save costs as
well.
Sustainability:
• Plastic used can be
recycled easily which
will safe the
environment.
Size/Dimensio
ns:
• Medium sized.
Safety:
• Shade is used to protect
overheating of the lamp,
this shade allows the
heat to resist.
• Soft edges are there, so
that there is no
roughness and there is a
better quality in the
product.
• It is stable so the is will
not fall over.Materials and
Manufacturing
Techniques:
• Fabric which is
heat resistant
coated this is
because it will
resist the heat
and will not
catch fire and
will not hurt
others
• A golden acrylic
plastic is used to
make a stable
base.
• Laser Cutter is
used to cut
Function:
• Main function
is to produce
light.
• Table Lamp

MATERIAL & JOINTS ANALYSIS
Dowel joint:
Description:
• Dowel joints are butt joints with
dowels used as reinforcements.
Holes are drilled in both pieces
and glue is used to secure the
dowels inn place and between
the joining surfaces.
Advantages:
• Cheap reinforcement
method
• Two or more dowels will
prevent work pieces
rotating if glue cannot
be applied
Disadvantages:
• Relatively
weak
• If holes are
drill accurately
the two mating
surfaces will
Description:
• Butt joints are the simplest form of
joint and the weakest since the only
have a small gluing area, which
means they can be pulled apart. They
are used in cheap furniture and
sometimes have dowels added to
reinforce them.
Butt joint:
Advantages
• Cheap
• Most simple joint
• Can be
strengthen
relatively easily
Disadvantages
• Weak due to
small gluing
area
Description:
• Mortise and Tenon joints are
widely used in the construction
of furniture frames. The
mortise is marked out with a
mortise gauge and cut with a
mortise chisel. The width of the
Tenon should be one third the
width of the timber
Advantages:
• Strong Joint
• Neat
Disadvantages:
• If not accurately cut
out the Tenon may
“float” creating an
unstable frame.
Mortice & Tenon joint:
Description:
• The Mitre joint is
another one of
those woodwork
joints that is almost
as easy to
construct and
make as a butt
joint. Even though
it is similar to a butt
joint this joint is
marginally stronger
Advantages:
• Neat
• Attractive joint
Disadvantages :
• Weak unless
reinforced,
needs mitre
saw to make
accurately
Mitre joint:
• Nuts, bolts and screws
provide a temporary fixing
and a convenient method
of securing parts.
• It also offer a reliable and
neat method of fixing
wood metal and plastic
Welding is a process in which metal part
are joined together by heating the
surfaces to the point of melting with a
blowpipe, electric arc, or other means,
and uniting them by pressing, hammering
and other.
Disadvantages:
• Edges of board are
unattractive and can't be
covered
• Not suitable for many
joints
• Still may contain natural
defects such as knots
due to the sheets of
veneer
Advantages:
• Very strong
• Light
• Resists cracking, bending,
warping, and shrinkage
• Can be made from most
timbers to increase
aesthetics
• Good for wood paneling
Plywood:
Advantages:
• It is cost
effective
• It's available in
many sizes
• Has no natural
defects
• Can be easily
machined
Disadvantages:
• Contains toxic resins which means
the saw dust created is dangerous
• Not suitable for most joints
• Should be fully sealed to prevent
toxins from escaping
• Can split
• Needs to be cut in ventilated areas or
in a room with a dust collection
system
MDF (Medium
Density
Fiberboard):
Advantages:
• Lightweight
• Cool
shapes
• Strength
• Style
Disadvantages:
• Distortion
• Scratches
• Expensive
Acrylic:
Disadvantages:
• An expensive
material
• Breaks easily
• Melts in high
temperatures
• When broken, the
pieces may be
Advantages
• Can be made in
different sizes and
objects
• Can be colored or
colorless
• Does not rust
Glass:

COMPONENT &
MANUFACTURING
ANALYSIS
Nuts, Bolts And Washers:
Component Analysis
Advantages:
• Can be undone so items can be taken
apart
• Come in various lengths and sizes
• Lock nuts can be used for firm fixings
Disadvantages:
• Can be displaced and lost on.
• Correct spanner must be used, other
wise nuts and bolts will become
rounded.
• Steel screws will rust if outside
Advantages:
• Energy efficient
• Long Lifetime
• No warm-up period
• Not affected by cold
• Excellent Color
Rendering
• Environmentally friendly
• Controllable
Disadvantages:
• A very limited variety and selection
• Hard to find in smaller towns
• Expensive
• Although they are available in many
colors, the quality of the colors is not
quite as good as with regular lighting
LED (Light emitting
diode):
Advantages:
• Capable of cutting many
materials and thicknesses
• Fast
• Easily and accurately
repeatable
• Reliable
Disadvantages:
• High power consumption
• Can be expensive
• Rate of production depends on
the material
• Poorly adjust lasers can cause
burning technology to minimize
this
Laser Cutting:
Manufacturing Analysis
Advantages:
• Ability to customize
products
• Rapid production of
prototypes
• Low cost of productionDisadvantages:
• Limitations of size
• Limitations of raw material
• Cost of printers and
electricity
3D Printer: Vacuum
Former:Advantages:
• Low cost
tooling
• Short lead-
time
• Complex
shapes
Disadvantages:
• Slow
manufacturing
cycle
• Relatively high
piece part cost
Advantages:
• Limited shape
possible to be cut
• Can cut straight
lines and tight
curves
Disadvantages:
• Long cutting,
preparation and
maintenance time
Band Saw:
Advantages:
• Removal of material.
• Preparation of
surfaces (adhesion
promoter).
• Smoothing the
surface and edges
• Reparation of
defects
Disadvantage:
• There are not quite any
disadvantages of
sanding machine, but
you need to place the
product/item evenly
Sanding
Machine:
Tenon
Saw:
Advantages:
• Limited shape possible t
be cut
• Plastic can cut easily
Disadvantages:
• Needs a lot of strength
and power (Physical
work)
Copping
Saw:
Saws:
Spray Paint:
Advantages:
• Speed and
Accessibility
• Even Coating
• Variety
Disadvantages:
• Irritant
• Toxic
• Can penetrate
the skin and
harm it.
Advantages:
• Fast and safe
• Low cost of
production
• Accurate and
consistency
• Efficient
Disadvantages:
• Cost, Expensive
• Errors: CNC machines do not totally eliminate
errors. Operators can still push the wrong buttons,
make incorrect alignments and fail to locate parts
properly on a jig.
CNC Machine:
Drilling Machine:
Advantage
s:
• It is
powerful
• It have
torque
control
Disadvantages:
• It can kick back
• Errors:. Operators
can make
incorrect
alignments and
fail to locate parts
properly on a jig.

DISASSEMBLY OF AN EXISTING PRODUCT
This lamp was bought from
IKEA. IKEA stores in UAE
offers a fine selection of
home furniture, lamps,
dining and many more.
This lamp is a table lamp,
which might be used for
studying or used for
different purposes such as
decoration, night sleeps
and many more.1. We firstly disconnected the lamp from
the power source by removing adaptor.
2. Secondly, detach the shade from the
lamp by losing the screws by screw
driver.
3. Also, separate the two parts of the
shape.
4. Thirdly, remove the LED light from the
lamp.
5. Moreover, disengage the different
parts of the lamp by untying the screws
by screw driver.
6. Furthermore, detached the base from
the lamp by unfastening the screws by
screw driver.
7. Likewise, remove the switch by
plugging out the copper wires.
8. Therefore the disassembly of the lamp
is completed.
Disassembl
y
21 3 4
5 6 7 8
9 10 11 12
Mini Components:
• 2 small screws
• 2 medium screws
• 2 fat screws
• LED (Yellow)
• Adaptor
• Switch case/cover
Before After
NOTE:
• Screw driver is used
to unfastening the
Product
Manufacturing:
• Acrylic Plastic is used
to make this product.
• Its function to give out
light.
• I think this product is
made by Mass
production. Mass
production is when a
very large number of
the product is made,

CONCLUSION BASED ON
RESEARCH
Research What I have found out? How will I use those information in
my Design Assignment?
Mood Board • Shape
• Color
• Theme (Architecture/Building)
• Designs
• This will give help me to give an idea
of the color, shape, theme and design
of my product.
Client + Questionnaire • My Client are those who can afford
the lamp I am thinking off, they are full
of colors and likes architecture.
• In the Questionnaire I have found
out the answers to my question….
Which was “How you I want my lamp
to look?”
• This will target my client, and will
make sure what my client want. I will
know what my client want by using my
Questionnaire answers.
Product Analysis • In my Product Analysis I have found
out the different things such as
techniques, the material made up of,
function, cost etc.…
• This will be me an idea on how
product must look, what will be the
function of the product etc.…
Material and Joint Analysis • I have found out the uses, advantages
and disadvantages of the material
and the joints
• This will give me an idea of what
material and joints should I use in my
lamp
Component and Manufacturing Analysis • I have found out the uses, advantages
and disadvantages of the
components and the manufacturing
techniques
• This will give me an idea of what
manufacturing techniques and
components should I use in my lamp
Product Disassembly • I have out how the product is
assembled and disassembled.
• I have also found out that how joints
(such as screws) are used.
• I have also found out that how the
product is manufactured.
• This will give me an idea on how to
make and assemble my product.
• It will give me any idea on how to
manufacture my product.

SPECIFICATION (DESIGN CRITERIA)/QUALITY
CONTROL CHECKSAESTHETICS/APPEARANCE:
• My design must look different from square,
rectangle and other regular shape and will not be
too big. This is because it will not remind us of
olden shapes, it will look eye pleasing and
attractive. My theme should be related
architecture. It is because what the client want
CLIENT PROFILE:
• The lamp will be sold to an airline company, a company with
many Customers and Clients. My client would be anyone, it
would be around all ages, means no age limits, does not
matter what he/she do, and does not matter what he/she likes
or dislikes. The only thing matter is the interest, my client
would be interested in buildings and architecture because my
lamp express these themes.
ENVIRONMENT:
• Light efficient bulb must be used. This is because it uses less energy and
produces less heat, and save costs as well.
• Eco-friendly materials must be used. This is because it can be recycled easily
and will not pollute the environment
COST:
• My design cost must not be too high or not too low, it will be
around AED 100-250. This is because of the materials are
cheap to buy, this means the cost will stay low for the
target market.
FUNCTION:
• My product must produce light. Its main function to give out
light is the most efficient way as possible. This is because
it will be effective sustainability, environmentally and
economically wise. It must give out light because we
need to solve our problem which is sated as: “First
class passengers have a less exposure to light
especially at night when the crew had switched off the
lights in the aircrafts when travelling abroad”
SAFETY:
• Stable base must be used. This is because the lamp might not
trip/fall over
• Soft edges must be used. This is because there should be no
roughness that will provide a better quality of life.
• Warm light must not be exposed because it can burn your finger
and body parts
SIZE:
• Medium sized lamp must be made. This is because it can it
can be easily transported or placed from one place to
MANUFACTURING & MATERIAL:
• My product must Mass production. Mass production is when a very large
number of the product is made, usually on a production line.
 It is because:
1. fewer labor costs.
2. faster rate of production,
• It must also have a butt joint if. This is because it is a cheap and easier
way to join two or more pieces of wood together, this creates better
surface area for adhesive to be applied while also concealing the end
grain giving it a nice flush look after sanding.
• The product must be spray painted, because it evenly paints the
product, its fast and is assessable to everyone, also it come in
different variety.
• My product must be made from Laser cutter, Band saw, Drilling machine
and CNC machine:
 Laser cutter because its fast, easily and accurately
repeatable.
 Band saw because its limited shape possible to be cut.
 Drilling machine because it perfectly drill smooth holes.
 CNC machine because its fast, consistent thru-put of finished
goods.
• It must be made out of Plywood or MDF and Acrylic Plastic.
 Plywood because it is less expensive, solid timber and almostAfter the research and getting the specifications, before making the
product, I must sketch it and develop it. Lets start.

INITIAL IDEAS (1)Sketch 1:
Sketch 4:
Sketch 2:
Sketch 5:
Inspired by
Mood Board:
Inspired
by
Mood
Inspired
by Mood
Board:
Inspired
by Mood
Board:
Inspired by Mood
Board:
15 cm
18
cm
15
cm
12.5
cm
14
cm
9 cm
11
c
m
10 cm
32
cm
25 cm
My design is
inspired from
mood board
therefore it links to
my theme, and
that’s what my
client want.
• My design color scheme is influenced by
the questionnaire, since wooden color,
white and black/silver color were the most
chosen color, from my client, these are the
color that my client want.
• The base is made out of plywood. It
is because it is a very strong. The
base is then cut into a triangular
shape it because it was the second
choice for the customer as per my
questionnaire, and then sanded
down for a smooth finish for a good
flush look. The wooden base is then
spray painted in black and a clear
coating is applied over it for a clean
finish in wooden color .
• LED lighting will be used, because it
saves energy, therefore it is good for
the environment. As per the
questionnaire that’s want my client
want.
• My design is made from plywood
and Acrylic. It is because that want
my client want. Also, Acrylic have a
lightweight therefore it is easier for
transportation and Plywood it very
short therefore it resist cracking and
breakage.
• The lamp is made from plywood and
laser cut Acrylic. It is because that`s
want my client want. I have used laser
cutter because laser cutter can cut
smooth edges quickly and effectively.
Acrylic have a good strength and
Plywood it very story therefore it resist
cracking and breakage. On Acrylic I
could engrave it to look aesthetically
good.• This design links
to my theme
because it is
chosen from
mood board and
that’s what my
• LED lighting is
used because it
saves energy and
that’s what my
client want as per
the questionnaire
Sketch 3: • The lamp is made from
plywood. Because it can be
made from most timbers to
increase aesthetics. Aesthetics
is one of the major thing that
most of the client look, as per
my questionnaire. Band saw
will be used to saw the pieces
of the wood. It is because it can
cut straight lines and tight
curves easily.
• This design links to my theme
because it is chosen from mood
board and that’s what my client
• LED lighting is used because
it comes in different color and
that’s what my client want as
per the questionnaire
• This design
links to my
theme
because it is
chosen from
mood board
and that’s
what my
client want.
• My design is inspired from mood
board therefore it links to my
theme, and that’s what my client
want.
• The lamp is made from laser cut
Acrylic. It is because that`s want my
client want. I have used laser cutter
reduces time for set-up with the
ability to react and adapt quickly to
changing production needs that are
market or quantity driven. Acrylic
have a good strength, comes in
different color and shapes etc....• LED lighting is used
because it is controllable
and that’s what my client
want as per the
questionnaire• My design color scheme is
influenced by the questionnaire,
since white and black/silver color
were the two chosen color.
These color are used because
that what my client want
• The lamp is made
from laser cut Acrylic
and Glass. I have
used Acrylic because
that`s want my client
want. I have used
laser cutter because
laser cutter can cut
smooth edges
quickly and
effectively. Acrylic
comes in cool
shapes while Glass
can come it different
sizes.
• LED lighting is used
because it have no
warming period time
and that’s what my
client want as per the
questionnaire

INITIAL IDEAS (2)Sketch 6:
Sketch 7:
Sketch 8:
Sketch 9:
Sketch
10:
Inspired by
Mood
Board:
Inspired by
Mood Board:
Inspired by Mood
Board:
Inspired by
Mood Board:
7.
5
cm
20
cm
10
cm
25
cm
14
cm
7
c
m
22
c
m
17 cm
15
cm
24
cm
Inspired by
Mood Board:
• LED lighting will be used, because it
saves energy, therefore it is good for
the environment. As per the
want.
• The lamp is made from plywood and
laser cut Acrylic. This is because
that`s want my client want. I have
used laser cutter because laser
cutter can cut smooth edges quickly
and effectively. Acrylic have a good
strength and Plywood it very story
therefore it resist cracking and
breakage.
• My design is
inspired from
mood board
therefore it links to
my theme, and
that’s what my
client want.
My design color scheme is
influenced by the
questionnaire, since wooden
color, white and black/silver
color were the most chosen
color, from my client, these
are the color that my client
want.
• My design is
inspired from
mood board
therefore it
links to my
theme, and
that’s what
my client
• The lamp is made from laser cut
Acrylic. It is because that`s want
my client want. I have used laser
cutter because laser cutter can
cut smooth edges quickly and
effectively. Also it reduces time
for set-up with the ability to react
and adapt quickly to
changing production needs that
are market or quantity driven.
Acrylic have a good strength,
comes in different color and
shapes etc....
• My design
is inspired
from mood
board
therefore it
links to my
theme,
and that’s
what my
client
want.
• My design is inspired from mood board therefore it
links to my theme, and that’s what my client want.
• My design
is inspired
from mood
board
therefore it
links to my
theme, and
that’s what
my client
want.
• The lamp is made from laser
cut Acrylic. It is because
that`s want my client want. I
have used laser cutter
because laser cutter can cut
smooth edges quickly and
effectively. Also it is capable
of cutting many materials
and thicknesses. Acrylic
have a good strength,
comes in different color and
shapes etc....
• LED lighting
is used
because it
is
controllable
and that’s
what my
client want
as per the
• The lamp is can be
made from MDF and
laser cut Acrylic. It is
because that`s want
my client want. I have
used laser cutter
because it is a efficient
process, as multiple
jobs or parts can be
inserted and cut in a
single program.
Acrylic have a good
strength and MDF is
durable material.
• The lamp is made from
plywood. Because it can
be made from most
timbers to increase
aesthetics. Aesthetics is
one of the major thing that
most of the client look, as
per my questionnaire.
Band saw will be used to
saw the pieces of the
wood. It is because it can
cut straight lines and tight
curves easily.
• LED lighting will be
used because . The
low voltage power
supply associated to
LEDs increases
electrical safety. As
per the questionnaire
that’s want my client
want.
• LED lighting will be used because .
The low voltage power supply
associated to LEDs increases
electrical safety. As per the
want.
• LED lighting will be used,
because it saves energy,
therefore it is good for the
environment. As per the
questionnaire that’s want m
client want.

EVALUATION OF THE SKETCHES
By evaluating the sketches against my specification I have found Sketch 1 and Sketch 2 links to my specification
more than the others therefore I will try to develop those sketches by making a prototype/model using CAD/CAM

DETAIL SKETCHES
6cm
7cm
25cm
12cm
12.5cm
12 cm

MODELING & MAKING A PROTOTYPE (1) USING
CAD/CAMI used 2D design to sketch the design of
product inspired from sketch 1. It is a
improved way where we can make a
prototype easily and quickly.
Shapes are close together, it is
because to prevent material
from wasting. One of the quality
check was in the environmental
part of the product was for it to
be as eco friendly as possible.
Blue Color as been
used to engrave the
material.
After the material is
engraved using the laser
cutter, I had cut the
outline of the shape
using a knife.
Protective
board is used
therefore it will
not damage
the table.
Glue Gun is
used to stick
the lose
pieces
together.
Front View Bottom
View
Top View
Side View
3D Model
Length x Width Quantit
y
12 cm x 10 cm 2
6 cm x 7 cm 4
25 cm x 30 cm 1
Cutting List
A cutting list is a organized list showing information about the materials required for
the job. It shows you things like: the kind of material needed for each part; how
much to use; length; width and thickness of the material; and any special notes on
what needs to be done.
So to complete a cutting list you need to:
• assess the specifications - consider what needs to be done
• identify the process to be used - this must include the materials and machining
sequence to be used
• complete the cutting list against specifications as outlined.Cutting List can be used and is really helpful for Batch production,
In batch production set quantities of a product are manufactured to order. Batch
production requires a high level of design, pattern making and sampling skills.
Materials are cost-effective and manufacturing costs are lower than one-off
production.
This is a 3D model (Prototype) is used to know the pros and cons of my product.
This prototype is made out of cardboard. I have used glue gun, paper, cutting mat,
craft knife and tape.
Health and Safety precaution should be taken while developing the prototype; such
as not touching the hot glue because it will burn your hand. In addition to this we
should keep the knife pointed downwards etc.…

MODELING & MAKING A PROTOTYPE (2) USING
CAD/CAMAgain, I used 2D design to sketch the
design of product inspired from sketch 2.
It is a improved way where we can make
a prototype easily and quickly.
Shapes are close together, it is
because to prevent material
from wasting. One of the quality
check was in the environmental
part of the product was for it to
be as eco friendly as possible.
How does glue gun work, it works
through hot melt adhesive (HMA),
also known as hot glue, is a form of
thermoplastic adhesive that is
commonly supplied in solid
cylindrical sticks of various
diameters, designed to be melted in
an electric hot glue gun. The gun
uses a continuous-duty heating
element to melt the plastic glue,
which may be pushed through the
gun by a mechanical trigger
mechanism, or directly by the user.
The glue squeezed out of the
heated nozzle is initially hot enough
to burn and even blister skin. The
glue is tacky when hot, and
solidifies in a few seconds to one
minute. Hot melt adhesives can
also be applied by dipping or
spraying.
Red Color as been
used to cut the material
using Laser Cutter.
Front View
Top View Bottom
View
Back View
After the material is cut
using the laser cutter, I
had stick the pieces
using glue gun
After sticking the pieces together
my 3D Model is made
Length x Width Quantit
y
16 cm x 12.5
cm
2
16 cm x 12 cm 1
Cutting
List
Cutting List can also be used and is really helpful for
Mass production, in mass production is the
industrial-scale manufacture of large quantities of
products, usually on a production line. Standardized
production methods mean it is suitable for products
that rarely need to be redesigned.
These were two of my prototypes, but why do we need
a prototype. A prototype is the first full-scale and
usually functional form of a new design. Why do we
need them because
• Fail early and inexpensively
• Gather more accurate requirements
• Resolve conflicts
• Technically understand the problem

STRENGTHS AND WEAKNESSES OF THE
MODELS
Model Of Sketch 1
Strengths Weaknesses
The sizes were a perfect fit,
all the pieces came together
due to the accuracy of the
measurements
The glue gun had good
effect, however it had
unwanted strings of hard
glue everywhere, which
brought a weak aesthetic
aspect to its part
It was manufactured through
pieces being cut in the laser
cutter, making it very easy.
Lack of colors made the
model look aesthetically
weak
It was very accurate due to
the fact it was designed on
CAD/CAM.
I could easily change the
sizes of the designs by
changing its structure in 2D
design (software), it
resembled exactly like the
drawing.
Model Of Sketch 2
Strengths Weaknesses
The pieces were not to big to
handle. It was a suitable size
with all the pieces to scale
The strings from the glue
which was made through
heating piece of plastic,
brought a weak aesthetic
look
The pieces were manufactured
through the laser cutter, so the
accuracy brought a more neat
and accurate look to it
Any extra force applied on
the glued pieces would not
be able to hold on as it
would just collapse and
break apart, clearly stating
the glue gun as a weak
adhesive
The base was really stable,
because of the extreme
flatness.

DEVELOPING MODEL & CLIENT OPINION
Using my prototypes I have developed different
models using the inspirations and the same style
from my prototype. I have chose one the best
model by asking my client what suits them the best
and developed the best model further to get as
accurate and best product for my client.
A good effort on developing the
product, aesthetically decent but
does not quite meets the
specification. This is too generic,
too simply can be much better.
Its size is too small. Lack of
ergonomics, function, and some
safety concerns for insistence
the sharp edges on the bottom,
at the base can be harmful for
Again a very good design, a lot of
things is good and meets the
specification such as its
appearance, function,
environment. But still there are
some problems, it does not fully
meets the specifications, its size is
too small. Safety concerns are
there such as there are sharp
edges on the bottom, at the base
No clarifications, this product
only met with one of my quality
check, questionnaire which is “It
must have curves and irregular
shape”. Other than that it does
not match the specification.
Anyways, good try.
I surely think you have worked hard
to get all these designs for me. Now
I think you should further develop
the Design 2 and show it to me.
CLIENT OPINION ON
DESIGN 1
CLIENT OPINION ON
DESIGN 2
CLIENT OPINION ON
DESIGN 3
FINAL COMMENTS

DEVELOPMENT (INCLUDING MESS
DEVELOPMENT)
I have used the advantages of prototype 1
and prototype 2 and tried to join these
prototype (model) to try in developing and
making a suitable and stable product
(lamp) for my client, many things went
quite well but there were things that
weren`t that great. Firstly, my product did
not quite meet the specification (or the
Design Criteria), it wasn`t very safe due to
it pointy base therefore I need to add a
different base to it. Also, the product might
very heavy because of the a lot of
plywood is used in the middle, therefore it
immobile and hard to transport from on
place to another. My design is not a Mass
production because I didn`t make the
cutting list, in order to improve I need to
make a cutting list Secondly, some of its
feature weren`t that good, For insistence,
there is lack of ergonomics, it hard for the
client to switch on and switch off the lamp
because there is no switches used client
can only switch on and switch off using
the mains, therefore need to add switch
so it will be easier for the client and user.
Prototype (1) Prototype (2)
Developed
Sketch
Issue MESS Development
Moral There are laws and standards I need to meet. These help to protect the users, by specifying that products
meet certain requirements and have suitable levels of safety. The Laws also allow consumers to get their
money back if goods are found to be faulty or if products do not perform in the way claimed by the
manufacturer.
A law is a formal rule adopted by Parliament and enforced by the government.
A standard is a guideline which is widely accepted. Standards do not necessarily have the force of the law.
LAWS:
• The Consumer Protection Act 1987
• The Trade Descriptions Act 1968
STANDARDS:
• KiteMark
• European Union (CE)
Environmental I have to make my product as eco-friendly as possible, I can do this by:
• Using LED than Light bulbs this is because its Energy efficient, therefore it environmentally friendly.
• Use timber because, timber is a renewable resource, which means timber is easy to reuse and can be
burnt to produce heat when at the end of its natural life. It is also biodegradable.
• While most plastics are not biodegradable, they can be recycled and reused
Sustainable My product should be recyclable and biodegradable.
• Recycling means reprocessing a material so that it can be used again. This helps to reduce damage to
the environment by reducing the need for new materials. For example, this might mean melting plastic
parts so that they can be shaped into new products. Symbols are used on plastic products to show the
type of plastic used, so that it can be sorted into different types and recycled.
• If it is essential to dispose of a product in landfill, ideally the material should be biodegradable. This
means that it will decompose (naturally break down) relatively quickly into naturally-occurring
substances - as opposed to non-biodegradable ones that take many years to decompose. Land filling
might bring some health, ethical and moral issues.
Social I need to make a product in which all cultural group will not be affected by a product, therefore I can ensure
that the design is suitable for the whole society.

Connects!
FINAL DEVELOPMENT
I connected four pieces of my
developing design, this gave me the
four identical shapes that revolve
around the circular base. When I
rotate the design I noticed that my
design have uneven curves therefore
I made one curve on each four
shapes that revolve the circular base.
I also noticed that the bottom ends
are sharp, and might harm someone,
therefore I changed my design into an
arc design. I also needed a base, I
made it simply for myself and went for
Circular
Base
Four identical arcs for my
body

FINAL DESIGN & CLIENT OPINIONI had this developing design on my left to start developing
further to get the most of the specifications right. This
design was chosen by my client. To start developing my
design, I connect four pieces of my developing design,
this gave me the four identical shapes that revolve around
the circular base. When I rotate the design I noticed that
my design have uneven curves therefore I made one
curve on each four shapes that revolve the circular base.
I also noticed that the bottom ends are sharp, and might
harm someone, therefore I changed my design into an
arc design. I also needed a base, I made it simply for
myself and went for circular base rather than a fancy
base. I already have a elegant and decent body, I did not
want to make it look strange with a fancy base, base it
needed for support. And this is how I have came to my
final design.
Developing
Design
Developed Design
Quality Checks Rating. (Best seven
stars)
AESTHETICS/APPEAR
ANCE
FUNCTION
COST ,SAFETY & SIZE
ENVIRONMENT
MANUFACTURING &
MATERIAL
Material Dimensions
(cm)
Quantity
Base (MDF) Radius = 14.42
Thickness = 2
x1
Arc 1 (Plywood) 1.2 x 1.2 x 27.6 x4
Arc 2 (Plywood) 2.4 x 1.2 x 28.3 x4
Arc 3 (Plywood) 3.6 x 1.2 x 30 x4
Cutting List
Simply, Decent design, looks good with
colors. Could have a top, but does not
matter. Over all very good model. Best one
CLIENT OPINION ON THE FINAL
DESIGN

ORTHOGRAPHIC DRAWING + EXPLODED VIEW OF
FINAL DESIGN White Arc
2
Green Arc
1
Black Arc
3
Red Arc 4
Bas
e
After the development, the final
design is ready to get under
Engineering/Orthographic
Drawing

MAKING (BODY)1
2
3
4
To start making firstly, using a circular
saw I cut 12 pieces of plywood. 4
pieces of 6.2 cm x 27.6. Second four
pieces of 7.8 cm x 28.3 cm. Third and
last four pieces of 10.2 cm x 30 cm. I
had to cut is using a circular saw
because the piece of Plywood was so
big, it was hard to mange since it was
heavy. Safety precaution were taken
into consideration since there are many
risks such as electric shocks, cuts and
amputations etc.. may occur. To
minimize the risks I used a plastic stick
to move the pieces. This will absorb all
the charges minimizing the risk of
electric shock since plastic is an
insulator. It will minimize the risk of cuts
since finger or body parts are not in
use.
After the manufacturing of the 12 pieces I have to cut each and every piece into arcs of the
same equal ratio and length. To do this I have to make a template. Templates are type
safe, because the types that templates act upon are known at compile time, the compiler
can perform type checking before errors occur, this limits the chances of error in making,
and also saves time since we human take long to measure accurately. Computer can
measure it accurately without errors. I have made the template on CAD (Computer Aided
Design) software know as 2D-Design. 2D- Design is really helpful for making design and
prototype, since it can have accurate measurements of any design. After making the
template on 2D-Design I have laser cut it using Laser cutter. Laser cutter cuts many
materials and thicknesses quickly, easily and accurately. Some safety precaution should be
taken such as put the extractor on to suck in of the toxic fumes which is harmful for human
life. This will increase the quality of life. After template have been cut, draw it on the 12
plywood pieces and start cutting.
After the templates had been cut draw it on 12
plywood pieces. To start cutting the pieces of
plywood, firstly using 3 cm circular drill, drill the 12
pieces to make the bottom arc. Drilling will give me
a smooth and flush arcs after sanding. I have to be
very careful when drilling. Safety measure should
be taken such as going slowly and at intervals to
prevent heat loss from the drill and harming the
wood. Also, I have wear goggles to prevent eyes
getting irritated from the dust, sand and fumes.
Also, protect myself and my fingers being cut,
therefore I used G-clamp to hold the pieces of wood
in place with the wooden base, therefore any of my
After drilling the circular arc, I
had to cut the left over
drawing from the templates.
To do this I used the band
saw o cut all the 12 plywood
pieces into arcs. Safety
measure were taken such as
wearing goggles to prevent
eyes getting irritated from the
dust, sand and fumes and
going slowly while cutting
since there is a chance to the
blade to come out and
Key:
Blue-Method
Green-Safety
Precautions
Italics-To answer WHY ?
Bold-Manufacturing
Techniques

MAKING (BODY)5
6
7 8
After cutting all the 12 plywood pieces, I had to
sand it down to get a nice smooth and flush finish
and look. I have sanded all 12 the plywood
pieces using a sanding machine and the inside
arcs using a sand paper. Sanding machine (belt
sander) is used for preparation of surfaces
(adhesion promoter), smoothing the surface and
edges & reparation of defects. Safety measure
should be taken unto consideration such as
wearing goggles to prevent eyes getting irritated
from the dust, sand and fumes. Also, I had to de
careful when touching the product after sanding
because the product will be warm due to the
fiction between the sand paper and the product
After sanding the product down I have took the 3 different plywood pieces and
using the wood fix glue I have stuck these pieces together and put it in vice. I
did this with the rest 9 pieces and have 4 pieces of plywood of different even
sized arc altogether. Ready to get paint. Wood fix glue is used to stick the two
or more pieces of wood together neatly using different joint in this case butt
joint is used. I made sure that the glue does not spill over, because this will
give me a week aesthetic look. I had to be careful when putting the product in
vice because the layer can slide over each other. Butt joint is used since it is
most simple joint and can be strengthen relatively easily.
After all the pieces are stuck together, then
come spray painting. Spray painting is fast
and is assessable to everyone, also it come in
different variety. My spray paint have a primer
and the color together therefore I did not have
to coated my product with the primer first.
Primer is used therefore the paint is not absorb
by the product, damaging the product. Safety
measure should be taken such as wearing
goggle, gloves and mask because air sprayers
use a lot of pressure to push out the paint. The
nozzle can penetrate the skin of fingers or other
body parts that get in the way of it, causing an
Acrylic Plastic will be add to the lamp on the open spaces
of the lamp to emit the light. To cut acrylic pieces I first
made it on the 2D-Design and printer on the laser cutter. I
cut some stars on the Acrylic pieces therefore it could
emit light with more intensity. Remember to put the
extractor on to suck in of the toxic fumes which is harmful
for human life. This will increase the quality of life.

MAKING (BASE)
3
1
2
4
The second part of my lamp was the to make a
base. It was important to have a base since
provide my lamp stability. To start making the
base firstly using the circular saw I cut two 12
mm thick pieces of MDF each of 32cm by
32cm big, and stick it the pieces together using
the wood fix glue. After sticking the pieces
together I put the MDF into the CNC machine
(Computer /Computerized numerical
control) therefore it could cut into a circle of
diameter of 28.84 cm. Extra spaces are used
on the MDF therefore the drill can move freely
in the CNC machine.
Before that, I went onto the Autodesk Inventor software and drew a 3D cylinder with a
diameter of 28.84 cm and a depth 24mm. Autodesk Inventor is a 3D CAD modeling
software used to design, visualize, and test product ideas. Inventor allowed me to create
product prototypes that accurately simulate the weight, dimension, and much more of
products and their components in a simulated 3D environment. Inventor also includes
integrated CAD simulation and design communication tools that not only enhances CAD
productivity and help to reduce errors but also can be integral in cutting development
timelines in half. After drawing I converted the inventor file into a .STL file and reopened it
in a another software. This software allowed me to use the CNC Router machine., so I
placed in the 2 pieces of MDF I had previously glued together (wood glue) in to the
machine for cutting.
I then started the process which took around 10-20 minutes.
After it finished cutting I sanded the base using belt sander. CNC
machine uses modern design software that allowed me to
simulate the manufacture my idea. This saves time and money.
But errors can occur CNC machines do not totally eliminate
errors. Operators can still push the wrong buttons, make
After sanding the base, using the drill I drilled 0.25cm hole for the
wire to pass. Safety measure should be taken unto consideration
such as wearing goggles to prevent eyes getting irritated from the
dust, sand and fumes. After drilling I spray painted the base with
white color. After painting and drilling, both body and base are
ready to get assembled using glue. Wiring will also be done before
3D viewer is used to view 3D shapes. The bottom
face is shown, the cut in done in the passage from
center through extrusion this is a passage for the
wires to go through

ASSEMBLY & WIRING (ELECTRONICS)
1
2 FINAL PRODUCT WITH AND WITOUT THE
LIGHT ON
After cutting all the pieces I collect
the pieces and started to assemble
them. To start assembling I joint the
pieces of Acrylic with the plywood
pieces using epoxy resin. Epoxy
resin have high mechanical and
thermal properties. It have high
water resistance, low cure
shrinkage. It is good for joining to
different material together. After
joining and sticking acrylic and
plywood pieces together, I joint the
body with the base using wood fix
glue.
Before assembly I did some
wiring to light the LED light. I
attached the earth, neutral and
live wire from the to the light
holder to the plug. The live wire
carries current to the appliance
at a high voltage. The neutral
wire completes the circuit and
carries current away from the
appliance. The third wire, called
the earth wire (green/yellow) is
a safety wire and connects the
metal case of the appliance to
the earth. This stops a fault
making the case of the
appliance live. Safety measure
should be taken into
consideration such as wearing
wrist band so all the charges are

1
PROBLEM WHILE MAKING AND THEIR POSSIBLE
SOLUTION
To start making the four arcs firstly, I started
cutting them using an electric hand saw. I
had to be very careful with the blade and go
slowly around the arcs keeping the blade
downwards. Before that I had to hold in place
the wooden block using G-clamp, this will
provide me the grip when cutting. After
cutting the first piece I noticed that the arcs
were not accurate and smooth, it does not
have a flush look. It wasted a lot of time.
This brought me to the to
the second solution which
was cutting the pieces of
wood using a band saw.
The results were similar to
the solution 1, expect the
time difference. Band saw
helped me to cut the
wooden piece within a
minute, Band saw cut
straight line not curves.
Two pieces of wood were
wasted until the 3rd Solution
came in place.
The third and final solution
brought me to the
conclusion on how to make
the product. I consulted
with my teacher, he gave
me an amazing idea. He
said I can use a circular
drill and cut down the arc
and the rest I could cut
using the band saw. This
was amazing, and the two
1
2
3
How to make the body of the product
?, with aesthetically pleasing arcs.
How to paint the body of the product ?
Hand Paint or Spray Paint.
2
1
2
3
I started of painting using a
paint and brush, but when I
finished two of the four piece, I
observed that the paint is not
attractive on the surface of the
body. Hand paint is very time
consuming and slightly more
costly, if the best quality one is
used. Paint was not ascetically
pleasing therefore I had to clear
it and paint it again.
After the hand painting, I had to fix
the problem. I wanted my paint to
be evenly spread on my product
therefore, I had to remove the paint
and clean my product. I then using
sand paper tried to clean up the
paint as much as I can to make the
paint smooth on the surface of the
body. I also used the thinner to
clean up the paint to evenly spray
over the paint.
After all of this, I started spray
painting the product. My spray
paint have a primer and the color
together therefore I did not have
to coated my product with the
primer first. Primer is used
therefore the paint is not absorb
by the product, damaging the
product. This saved a lot of time
and give me a classic finish with
even and smooth paint

CLIENT & GENERAL PUBLIC
OVERVIEW
Public is willing
to pay
AED 50-
100
AED
101-150
AED
151-200
AED
201-250
Size
Mass/Weig
ht
Others
Things people did not
like in my Lamp
Size Mass/Weight Others
33%
39%
15%
13%
THINGS PEOPLE LIKE
IN MY LAMP
Color Shape Function Others
Will you buy ?
Yes No
Client
Feedback:WOW!, an amazing,
decent and elegant
product. It is really very
ascetically pleasing. It
matches most of the
specification and quality
checks.
It needs a bit more
improvement, I have
some concerns regrading
some production issues,
it took a lot of time
making this product. Rate
of mass production is
very slow. Mass/Weight
of the product is
considerably huge
because a lot of plywood
is used in the middle,
therefore the rate of
mobility is very slow.
Now you have to come

CONCLUSION BASED ON
SPECIFICATION
MANUFACTURING & MATERIAL:
• My product must Mass production. Mass production is when a very large
number of the product is made, usually on a production line.
 It is because:
1. fewer labor costs.
2. faster rate of production,
• It must also have a butt joint if. This is because it is a cheap and easier
way to join two or more pieces of wood together, this creates better
surface area for adhesive to be applied while also concealing the end
grain giving it a nice flush look after sanding.
• The product must be spray painted, because it evenly paints the
product, its fast and is assessable to everyone, also it come in
different variety.
• My product must be made from Laser cutter, Band saw, Drilling machine
and CNC machine:
 Laser cutter because its fast, easily and accurately
repeatable.
 Band saw because its limited shape possible to be cut.
 Drilling machine because it perfectly drill smooth holes.
 CNC machine because its fast, consistent thru-put of finished
goods.
• It must be made out of Plywood or MDF and Acrylic Plastic.
AESTHETICS/APPEARANCE:
• My design must look different from square,
rectangle and other unvarying shape and will not
be too big. This is because it will not remind us
of olden shapes, it will look eye pleasing and
attractive. My theme should be related
architecture. It is because what the client want
CLIENT PROFILE:
• The lamp will be sold to an airline company, a company with
many Customers and Clients. My client would be anyone, it
would be around all ages, means no age limits, does not
matter what he/she do, and does not matter what he/she likes
or dislikes. The only thing matter is the interest, my client
would be interested in buildings and architecture because my
lamp express these themes.
ENVIRONMENT:
• Light efficient bulb must be used. This is because it uses less
energy and produces less heat, and save costs as well.
• Eco-friendly materials must be used. This is because it can be
recycled easily and will not pollute the environment
COST:
• My design cost must not be too high or not too low, it will
be around AED 100-250. This is because of the
materials are cheap to buy, this means the cost will
stay low for the target market.
FUNCTION:
• My product must produce light. Its main function to give
out light is the most efficient way as possible. This is
because it will be effective sustainability,
environmentally and economically wise. It must give
out light because we need to solve our problem
which is sated as: “First class passengers have a
less exposure to light especially at night when the
crew had switched off the lights in the aircrafts when
travelling abroad”
SAFETY:
• Stable base must be used. This is because the lamp might not
trip/fall over
• Soft edges must be used. This is because there should be no
roughness that will provide a better quality of life.
• Warm light must to be exposed because it can burn your finger
and body parts
SIZE:
• Medium sized lamp must be made. This is because it can it
can be easily transported or placed from one place to
My product must be a mass
product, but the process took too
long. The rate of production was
very slow. I have to come up with
a solution for this.
The top was open therefore it is easy to put the
hand in and burn your finger with the flaming hot
bulb.
Green- Achieved
Brownish Orange- Moderate
Red- Not achieved
Black- Explanation why its moderate or not
achieved
Key
:
The product was a bit

EVALUATIONAfter Conclusion and the
client/public overview I tried to make
a mind map of the product and
analyze the faults and mistakes in
my product and modify some of the
specification, to get the best product
possible. I then try to modify the
product by my modified specification.
Aesthetics/
Appearance:
Functio
n:
Cost, Safety & Size:
Environment:
Manufacturing & Material
 I could try to improve the painting strategy,
to evenly paint my product`s body I must
go slowly and apply the paint in each and
every part with correct timing.
 I could have use a cleaning tool to clean
all the stain in my product.
 I could have sand my product a bit more,
therefore it can shine and aesthetically
pleasing finish.
 Safety is one of the main concerns of
my client, to make my product a bit
more safer I could have sanded my
product a bit more. Also I could have
added a top that will prevent the skin
from burning, from the warm yellow
LED light.
 I could have decrease the cost by
investing less money in making the
product.
 I could have made a small-medium
sized product with less mass
therefore it is easier for
 The main function of my
product is to give out light. My
product could function a bit
better if I could have a switch
or dual lighten etc. This will be
user friendly. And will increase
its functions
 I could be a bit more efficient
in making this product, I
could be efficient with the
resources (such as paint,
acrylic, and wood) as
possible
 My material choice and manufacturing
techniques were perfectly fine at
individual level. To make this product at a
commercial level I can`t use the same
method, material and technique used in
making on product. Therefore I have to
modify the whole product and try to solve
all the issues. Modified product must be
different than product manufactured. I
must to solve the mass production issue.
 Why do we need to produce the product
as mass production?
Mass production is the name given to the
method of producing goods in large
quantities at low cost per unit. But mass
production, although allowing lower prices,
does not have to mean low-quality
production. Instead, mass-produced goods
are standardized by means of precision-
manufactured, interchangeable parts. The
mass production process itself is
characterized by mechanization to achieve
high volume, elaborate organization of
materials flow through various stages of
manufacturing, careful supervision of quality
standards, and minute division of labour. To

MODIFICATIONS & MASS
PRODUCTIONAfter analyzing the product I must modify it trying to
overcome all the problems.
Taking into consideration all the faults I have
develop the product overcoming all the problems.
My modified product now gives the solution to the
problems.
Mass
Production:To make a product that will be a mass production, I can`t make the product
with the same process that I used earlier, therefore I have to come up with
an alternative solution. Mass production will be at a big industrial level.
To start making the body of
my modified product at a
large scale, I will use
injection moulding technique.
The plastic injection
moulding process produces
large numbers of parts of
high quality with great
accuracy, very quickly.
Plastic material in the form of
granules is melted until soft
enough to be injected under
pressure to fill a mould. The
result is that the shape is
exactly copied, this safes
time and money. This is the
best process of make
Mass/Weight:
My modified design does not have a lot of
plywood in the middle, since plywood was
increasing the mass of the total product.
Rather than plywood I used plastics because
plastics are biodegradable and can be
recycled this is good for the environment and
saves money. Also, the rate of mobility will be
quicker since it is easy to transport and carry.
Safety:
My modified product does
not have any sharp edges
and will not hurt any
users. My lamp is fully
covered therefore the
warm light will not affect
any users.
Size:
My modified product is
not to big and too small
for my client.
To make a base and a stand of my
modified product, I will you a CNC
machine. Computer /Computerized
numerical control (CNC), is in which
computers play an integral part of the
control. Motion is controlled along multiple
axes, normally at least two (X and Y), and
a tool spindle that moves in the Z (depth).
The position of the tool is driven by direct-
drive stepper motor or servo motors in
order to provide highly accurate
movements. Open-loop control works as
long as the forces are kept small enough
and speeds are not too great. On
commercial machines, closed loop
controls are standard and required in order
to provide the accuracy, speed, and
LED (Light Emitting Diode), are cheap to
buy and use, wiring can be easily done.Problem
1
2
3
4
Modified
Plasti
c
Mould
Wooden
Stand
Wooden
Base

GCSE Product Design

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