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GCSE Product Design

The document outlines the process for designing a new product from research through development, manufacturing, and evaluation. It includes sections on conducting research like a design brief, questionnaire, mood board and analyzing existing products. It then covers the iterative design process from initial ideas, modeling, and specifications. Later sections discuss taking the final design through development of drawings, models, testing, manufacturing, and final evaluation against specifications. The document is organized into the main stages of research, development, making, and evaluation.

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Content1. Design brief, Context and Problem 2. Questionnaire 3. Mood board and client profile 4. Existing products analysis 5. Disassembly of a home lamp 6. Basic Components analysis 7. Manufacturing Research 8. Joint research 9. Research summary 10. Specification/Quality control 11. Initial ideas/Design analysis 12. Initial ideas specification analysis/ranking/match 13. Development of sketches 14. Model dimensions for developed designs 15. Sketch 5 development modeling 16. Sketch 8 Development modeling 17. Strengths and weaknesses of the models 18. Final Design 19. Orthographic drawing and components of the product 20. Model of the final design 21. M.E.S.S Development 22. Testing and development/modification in final design 23. Making Diary 24. Evaluation against specification/Quality check 25. Evaluation-Opinions 26. Modification 27. Evaluation- overcoming problems + Mass production Research Development Making Evaluation 3-14 Page Number 3 4 5 6-8 9 10 11 12 13 14 15-17 18-19 20-21 22 23 24 25 26-27 28 29 30 31 32-35 36 37 38 39 15-31 32-35 36-39
Problem Kids between the ages of 10-20 (teenagers) usually study the whole night in either dim light or a lot of light (which is not cost effective), they require personal lamps which are cost effective and not eye damaging Design Brief I am going to design and manufacture a working personal lamp for teenagers who work very hard for their exams in the night times. This lamp will protect their eyes from any further damage and any stress induced by the lights. This should improve their efforts in study and produce much more quality and standardized grades. Design Brief, Context and Problem
0 2 4 6 8 10 12 14 16 Column1 Red Blue Yellow Black Purple Green White Gray What type of lighting would you prefer? 4% 40% 6% 20% 30% Types of lighting HID LED Halogen fluroscent Energy-saver What aspect of the lamp do feel as vital to its selling? 30% 20% 10% 20% 20% Aspects of a product Asthetics Cost Function Material Others What 3D shape do you like on a lamp? 11% 38% 4% 31% 10% 6% Shapes Tube lines Sphere Cylinder cuboid Irregular 3D shape others 70% 4% 16% 10% Basic inspiration Star Wars® The Guardian Of The Galaxy® Star Trek® Prometheus® What Sci-Fi movie should inspire the main design of the lamp? Mains or battery? 70% 30% Energy source Battery Mains Conclusions from questionnaire data • Black, white and red should be thought being used the most • Aesthetics plays a major role in selling the lamp • LED is preferred over HID, Halogens, Fluorescent and energy saver • My clients prefer a lamp to consist of spherical and/or cuboidal shapes • Star wars® should be the main inspiration base of the lamp • Mains would suite a lamp more than a battery socket • People are willing to 60 pounds for this product Questionnaire
Client Profile My product will be on any furniture or lamp store, or even online on websites such as eBay, amazon etc. People between the ages of 10-20 would be interested in my product, mainly fans of top cinema box movies such as Star Wars®, Prometheus®, Star Trek® etc. It gives a theme of Sci- Fi and space. It also shows the correlation between these themes. My client would be someone who is interested in the modern style of certain things as show pieces, and my product is a perfect example of modernization at its best. This lamp would fit perfectly in a teenagers bedroom, which would show his interests and passion. Mood board and client profile
Existing Products Analysis
Aesthetics • A combination of different shapes • A mixture of 2D and 3D shapes • One certain color to attract certain audience • 2D shape around the globe replicates a gas ring of a planet in out solar system • Orange color to replicate a gas planet • Circular to portray a stereotypical shape for a planet. Client • For people aged from 7-16 years old • Space theme to attract astronomy lovers • Clients who prefer the color orange over the variety of others, due to personal preferences Cost • 100 DHS • Costs of labor and work rate from workers • The cost of manufacturing when in mass production • Different components manufactured differently, so the prices vary • Different materials used and so a range of prices are noticeable Function • An everyday use lamp for a child/teen • A plastic ring to make it more realistic • A light bulb to give the glare in a room • Orange color which enhances the glare of light emitted by the bulb • A switch to flick it on and off at mood. Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • An open mouth for the heat to escape or else the plastic would start to burn and could cause a fire • An insulating wire which is safe for human contact • Plastic which does not overheat that often and quickly Size • Size suitable for a room table • About 30 cm tall and 45 cm wide • Simple size for a child/teen to use • Does not overtake place Material • Acrylic used for mass production of lamp • Glass used for bulb enhance the effect of light • A rubber wire to make it an insulator, prevent shock accidents Aesthetics • 2 different light sources to make it eye-catching • Has an irregular shape • Inspiration from squiggly lines • The black base complements the flair lighting • LED lights bring more information • The colors blue and pink contrast each other perfectly. • 2D and 3D shapes vary the looks Client • For people who are interested in astronomy and nebulas etc. • Blue and pink color fans • Teens over the age 10+ • Teens who are capable and intellectual to understand its function Cost • About 250 DHS • Many different process and manufacturing ways raise the bar • Different sorts of materials used • More electronics are involved with this • LED lights can cost a fortune Function • LED lights give it a more astronomical look • LED lights enhance the glaze effect, so do the colors • The switch is there to make is simple and easy for the customer to understand • Shape expanded in the area to spread light further • The LED lights are there to create and enhance the effect of normal lights • The base is to hold the LED lights and the switch connected • The base allows a group of wire to pass through. • The switch is there to turn the lamp on and off at mood Environment • The LED lights release heat • The plastic used for the base is made from oil, which is a finite source • Used battery to make it more environmental friendly. • Glass made from extreme pressure and heat, which could have possibly released deadly toxins into the atmosphere Safety • If left in a place of immense heat, batteries can explode • The glass can break and can injure people • The switch must be made from an insulator to prevent shocks the fact that Size • Has a thick base with a very tall LED light shaped as an irregular shape • Length about 45 cm • With is about 15 cm • The short width and tall length provides a push to spread the light in a dark room Material/Manufacturin g • Glass is there to cover the LED light to enhance the effect of light dispersion • Plastic base so that it insulates the electricity passing through • Switch also a plastic insulator • Different sort of procedure used • Laser cutter to cut out the base • Glass welding to create the shape Anthropometric/Ergon omic • The average size of an index finger can then provide the dimension for the switch Anthropometric/Ergonom ic • The average size of an index finger can then provide the dimension for the switch Aesthetics • A circular shape resembles a star • The black covering adds a bit of spice and excitement to the lamp, seems like its armored • A replica of the ‘death star’ from the movie star wars • The colors black and white complement each other perfectly • The holes on the black belt create a more catchy design appearance Client • For Star Wars fans • Teens above 10+ • People who are interested in the depths of space Cost • About 300 DHS • Different sort of manufacturing methods cost more • More materials cost more • Labor is not cheap nowadays Function • The LED is covered with a spherical shape which disperses the lights further • The black belt around out create a fancy lighting show. • The button on the bottom Is to turn it on and off at will • The black belt provides itself as a stand so that the lamp does not roll everywhere Material/Manufacturing • Glass used for the sphere to enhance the lighting for that • The black belt created through acrylic through injection molding • Holes created using laser cutting machine • Mostly used glass, acrylic or some sort of rubber plastic for the switch to make a perfect insulator Manufacturing • The ring was created through laser cutter • The cover is created through injection molding Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • The bulb is covered to prevent heat from escaping • Its spherical which prevents a injuries to occur • An insulating wire which is safe for human contact • Plastic which does not overheat that often and quickly Size • Size suitable for a room table • About 30 cm tall and 45 cm wide • Simple size for a child/teen to use • Does not overtake place Anthropometric/Ergono mic • The average size of an index finger can then provide the dimension for the switch
Aesthetics • A ring to present meteorite fields. • A light blue LED to show the light in space from the stars • The irregular shaped base to represent the flying saucer of a UFO • Black and Blue compliment each other perfectly • Variation in the type of shapes available Client • For people who are interested in space and time • Intrigued about UFOs • Interest in Sci-fi • Aged 10+ Cost • 200 DHS • The LED light costs a lot due to its color • The base manufacturing is expensive • Money to be payed for assembly Function • The color of the light is there to enhance the level of brightness • The base is made curved to make it stable • Its there to give a more astronomical look • The switch allows you to turn it on and off at will. • The hole in the middle allows a hand to go through and carry the lamp where ever you want. • Makes it more portable Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • An open mouth for the heat to escape or else the plastic would start to melt • The base consists of sharp vertices which can be dangerous to underage kids Size • Must be 20 cm X 25 cm • The diameter of the circle should be 10 cm Material • Acrylic will be mostly used due its variety • LED light will be covered by either some heat insulating plastic or a glass that does not absorb heat • A good insulator for the switch Aesthetics • Blue light used to portray the color of the galaxy • A flat base shows how the universe looks from earth • Many mini lights portray the stars blinking in the sky • The brown color of the base compliments the black and blue Client • Who are interested about the expansion of the galaxy • Also those who follow the horoscope • Aged 10+ • People who understand how to work hand sensors Cost • About 250 DHS • Many different process and manufacturing ways raise the bar • Different sorts of materials used • More electronics are involved with this • LED lights can cost a fortune • Has a hand sensor Function • LED lights are there to enhance the brightness • The base is designed that way to make is stable and stand up still • The lights extruded from the base are done to bring a more realistic effect to the lamp • The lights are designed with a movement detector, as the hand waves pass the lights turn on igniting the room • The extrusions are aiming everywhere in a 180 angle to disperse the light even further Environment • The LED lights release heat • The plastic used for the base is made from oil, which is a finite source • Used battery to make it more environmental friendly. • Glass made from extreme pressure and heat, which could have possibly released deadly toxins into the atmosphere • The sensor could need more materials which could release toxins when being manufactured Safety • The extrusions could injure a person • The base could slip and fall on the ground and hurt somebody somehow • The lights could be damaged due to the excessive extrusion Size • Has a thick base with a very tall LED light shaped as an irregular shape • Length about 60 cm • With is about 15 cm • The short width and tall length provides a push to spread the light in a dark room • The light extrusions provide a better sensor position for it work Material/Manufacturing • Glass is there to cover the LED light to enhance the effect of light dispersion • Plastic base so that it insulates the electricity passing through • Switch also a plastic insulator • Different sort of procedure used • Laser cutter to cut out the base • Glass welding to create the shape Anthropometric/Ergonomic • The average size of an index finger can then provide the dimension for the switch • The average hand size is surveyed and found out, and then the ring is cut through that size because the hand will be going through it, to make is portable Anthropometric/Ergonomic • The average size of an index finger can then provide the dimension for the switch • The average surface area of a human hand is measure and the sensor is then detected on that measurements basis Aesthetics • A cuboidal shape resembles a part of a spaceship • The white color of the lamp provides it with a calm and composed look • The engraves flowers provides and deep insight and a meaning to the manufacturers thought process Client • For those who enjoy Sci-Fi • Teens above 10+ • People who are interested in the depths of space Cost • About 300 DHS • Different sort of manufacturing methods cost more • More materials cost more • Labor is not cheap nowadays Function • The LED is places inside the cuboid which allows the to disperse a white color • The flower engravement provide the magnification of a flower shadow • The button on the bottom Is to turn it on and off at will • The square base makes it stable showing perhaps how it will not fall Material/Manufacturing • Glass used for the sphere to enhance the lighting for that • The black belt created through acrylic through injection molding • Holes created using laser cutting machine • Mostly used glass, acrylic or some sort of rubber plastic for the switch to make a perfect insulator Manufacturing • The ring was created through laser cutter • The cover is created through injection molding • The Hole was creates through laser cutting Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • The bulb is covered to prevent heat from escaping • Its spherical which prevents a injuries to occur • An insulating wire which is safe for human contact • Plastic which does not overheat that often and quickly Size • Size suitable for a room table • About 30 cm tall and 45 cm wide • Simple size for a child/teen to use • Does not overtake place Anthropometric/Ergon omic • The average size of an index finger can then provide the dimension for the switch
A working IKEA® lamp, basically used for studying in the nights or for when there is no light available in the room We firstly detach the base made from plastic which holds the is a step down mini transformer, it reduces the volts coming in from the mains which could damage burn the LED light We then detach the glass covering the LED light which prevents it from over heating the plastic and causing harm to the consumer. We use a 4 faced screw driver to remove the glass leaving the LED light exposed and detached from its position As you can see the LED light slot has been completely removed from it origin, plastic covering to prevent heat waste. We then detach the power source from the power switch, it requires just physical force and it comes out. We also remove the top retractable arm which is used to change the direction of the light Mini Components • 15 screws • 6 set of wires (copper) • Black plate-inspired bearing The power source is left as it is, the red wires, made from copper (conductor)are connected to the power switch and the blue wires are connected to the mains fuse, these wire complete the flow of current allowing the lamp to work • LED light (yellow) • Glass piece (circular • 2 bolts • 2 mini bearings Disassembly of a home lamp 1 2 3 4 5 Conclusions from Disassembly analysis • Make sure that your product can be disassembled easily • Try not to make it too complicated • Avoid over fitting components • Sensibly choose material depending on assembly and disassembly • Limit the screws, nuts, and bolts you are using during the manufacturing • Material should prevent over heating • My lamp would need to look better in its aesthetics, than this, as it is the most important aspect.
Screws and bolts Advantages • Easy to attain from anywhere • Simple to fix, attach or assemble • Very cheap in the market, can be bought in large numbers • Provide tight joints • Prevents parts from falling apart Disadvantages • During the assembly, the screw or bolt should not fracture the material • From materials like acrylics, the nuts will become loose • Makes it looks messy • Doesn’t go well with weaker woods such as ply wood. Glass Advantages • Gives it a more production look • Produces better quality light then acrylic • Comes in many types Disadvantages • Over a time period, scratches start to appear • If it falls it will definitely break and shatter into pieces • Comparatively expensive to acrylic Plywood Advantages • Layers are glued together in right angles, which give it strength • Plywood is cheaper than other wood, a cheap wood which provides more strength than some expensive wood Disadvantages • The layering affect makes it porous and susceptible to water • Nuts and bolts can fracture the wood, so must be careful when manufacturing it Acrylic Advantages • Light weight, so its easier to manufacture and move around. • Style, it brings more style to a product than bland wood • Strength, difficult to bend or crack Disadvantages • The acrylics is easily scratch able • It does not produce the light quality as glass • Difficult to assemble MDF Advantages • A very inexpensive woods • It can be painted or stained to look just like normal woods, nice substitute of wood without paying the full price Disadvantages • MDF is weak compared to other woods • Due to it lack of density, more nails will be required to install it for the different places in the lamp • Nails can actually fracture the wood, damaging your whole product. LED lights Advantages • Energy efficient • No warm up period, doesn’t heat up which could melt the plastic • Environmental friendly, releases almost no waste energy • Excellent color rendering Disadvantages • LED are currently more expensive to use in mass production compared to other lighting sources • LED performance largely depends on correctly engineering the fixture to manage the heat generated by the LED • Must be supplied with correct voltage • LEDs shift color due to age and Spray Paint Advantages • Speed and accessibility • Even coating • Variety • High resistant to UV degradation • Wide range of effects Disadvantages • More skill required for even coat • More expensive than powder or liquid paint • Not as tough as powder • Solvent emission not good for environment Basic Components Analysis
Manufacturing Research Band Saw Advantages • Allows any lines and shapes to formed on the wood or acrylics being used • Can also cut through acrylics and other plastics/woods Disadvantages • Band saw can crack/fracture the material being used • Starts to create a lot of bird or rough edges on the acrylic/woods. 3D printing Advantages • It has the ability to customize products • Rapid production of parts and prototypes • Not much expense is required Disadvantages • It does have a serious limitation of size, it can only produce until a certain size • Limitation of raw material, mistakes a viable, so raw material might start become an issue • Has a high electrical cost Vacuum Forming Advantages • Low cost tooling • Short lead time • Complex shapes easy to because the mold is easy to manufacture Disadvantages • It has a slow manufacturing cycle, longer time is required to provide the producer with the finishing good • Relatively high piece part cost, sometimes its components which need to be replaced are at high costs. Laser Cutter Advantages • Capable of cutting many materials and thicknesses • Cutting narrow kerf widths, which promotes efficient part nesting, yielding better sheet utilization and material savings • Easily and accurately repeatable • Reduced time for set-up with the ability to react and adapt quickly to changing production needs that are market or quantity driven • Efficient processing, as multiple jobs or parts can be nested and cut in a single program. • No secondary clean up process required for most materials, and is usually ready for immediate shipment Disadvantages • Poorly adjusted laser can burn the acrylic and cause a fire • Rate of production can be determined by the density of the material • Higher power consumption • Electrical cost is very high • Usually just 2D cutting Belt Sander Advantages • Used for the perfect finishing for wood basically • Acrylic can also be used on this to cut of bird and rough edges • Gives it a smooth and fine finish Disadvantages • Must be careful to check out the proportion of sanding. • Sometimes unevenness is created on the product • If human skin rubs on it, friction burn is caused and is damaging. Tennon saw Advantages • Used to cut wood pieces of all types. • Brings an even shape between 2 cut wood pieces Disadvantages • Requires a lot of physical force • Can slip and cut your skin • Friction burns are very common Coping Saw Advantages • Used to cut acrylic/plastics easily • Can bend while cutting and changing direction is possible • The blade gives a free move to the cutting Disadvantages • Requires a lot of physical force • Blade usually breaks/cracks all the time, spare must be available • Repair costs a lot • Cut cause friction burn or slip and cut your finger/skin
Joint Research Butt Joints A very simple joint but it is also very weak. They tend to be used for making picture frames, corner pieces and nails are often used to strengthen the joint. Advantages • Easy to design • Fits together with glue, no technicality Disadvantages • Weak joints, the glues usually wears out, especially when its acrylic • During assembly, placement can go wrong Mitre Joints Mitre joints are often used to produce the corners of picture frames and boxes. The mitre needs to be cut at a 45 degree angle, this is often used with a mitre saw that can cut at many different angles. Advantages • Easy to design • Fits together with glue, no technicality Disadvantages • Angles can be damaged or compromised during manufacturing • During assembly, placement can go wrong Finger Joints This is the strongest joint on this page, the only joint that is stronger is the dovetail joint. The finger joint can be difficult to make but looks very good. It has a lot of surface area to glue together Advantages • Larger surface to glue together • The technique makes it more durable Disadvantages • Very technical, all dimension must be taken into consideration • Sanding in order to improve aesthetically can damage the fitting Housing Joints This is just a simple slot cut into one piece of wood to increase the glue area. This is often done with a router and works very well in MDF. Advantages • Very simple to generate • Glue area increases, improving durability Disadvantages • Assembly can be tough • Fitting is very important to be spot-on
Research What I found out? How will I use this information in the manufacturing of the product? Mood Board • In my mood board there was a large number of spheres • Large quantities of images taken by telescopes in space • Seem very futuristic and artistic in a way • Try to impose a sphere in my final design, especially when its voted the top shape in my questionnaires • Bring a futuristic, Sci-Fi and space effect to it Questionnaire • Sphere was chosen as the favourite 3D shape • People chose battery over mains. • LED lights received the majority of the 50 people vote • People want a link with the movie Star Wars®. If possible, but not necessary as it should more importantly be linked to Sci-Fi and space • People are only willing to pay 60 pounds for a sci-fi lamp • I need to somehow impose the sphere shape in to increase the sale price or quantity • The argument on mains or batteries is comprisable. • The colours should basically be the ones voted the highest • Make the product as cheap as possible, with the highest quality to achieve maximum profit Product analysis • Every product definitely has its pros or cons • Always try to reduce the cons for better production • The lighting must used safely. (heat as waste) • Colour combination improves the most important aspect, Aesthetics • Figure out the pros and cons, and try to unbalance them out, in a way that the pros are greater than the cons • Figure out how much voltage or energy the light in your lamp will require, would you need a resistor if its connected to a mains? Basic components analysis • Limiting the nuts and bolts decreases the probability of a fracture or a damage. • Plywood is stronger than MDF, however, plywood is porous and susceptible to water. • Spray paint is the best option when it comes to painting wood • Try to reduce the bolts used in both acrylic and wooden part of the lamp • I would use plywood because the strength basically matters, because no one is going to take it close to the water. • LED lights produce the least waster energy after the light saver and the fluorescent light, but it provide better quality Manufacturing Analysis • To make a sphere, I would have to use either the 3D printer or the vacuum former • For the base using the tenon saw would be best • To shape and cut through acrylic, a coping saw is ideal, though it is easily damageable. • It should be as efficient as possible, use up maximum amount of the resource, not wasting any • I will have to look into more detail in which is the ideal machine to use for creating a sphere, would it be the vacuum former or the 3D printer? • The base is basically going to be either a cuboid or cube inspired shape or it could just be any wooden base. • It should be hollow from the inside because that’s where the mains or battery socket wires will have to go • Any acrylic part of the lamp must be crafted either using a laser cutter or a coping saw if u want it hand craft rather then CAD/CAM-ed. Disassembly • Limiting the mini components eases the manufacturing process • Makes it easier for mass production, the manual is not that condensed with content. • Choosing material wisely, depending on manufacturing process and mini components • Should basically be easy in assembly and disassembly • Material should prevent over heating • Make sure that your product can be disassembled easily • Try not to make it too complicated • Avoid over fitting components • Sensibly choose material depending on assembly and disassembly • Limit the screws, nuts, and bolts you are using during the manufacturing • Think about the consumer or the assembler, how should you make it, so that’s easy to assemble and disassemble • How would I make it that it would make life easier for a illiterate consumer and an unskilled worker • Plastic would be most suitable to prevent my product from over heating.
Specification/quality control Function • It should provide sufficient amount of light for reading or studying • It should be portable anywhere around a room • The on and off button must be working flawlessly Aesthetics • My product should follow my Sci-Fi/Space theme • Lamp should not have any bird edges, or anything that makes it look messy • It must have majority of the colors which were chosen in the questionnaire • No rough edges of the wooden base or any dripping paint be visible to the costumer Safety • It should not have anything pointy sticking out of it, because my product is basically for teenagers, who make harsh decision very quickly • It should be in a state where it falls of anywhere it is kept, because if it consist of glass, then it will shatter everywhere Size • As the majority of my clients stated that he/she wanted between 30cm^2 – 50cm^2 • Must consist the shapes which were chosen at a majority between the 50 people such as a sphere or a cuboid Customer • Its mainly for people between the ages of 10-20 (adolescents) • For people who are into the Sci- Fi/Space theme • He should also have interest in mechanics, technology and modern looks Material • As I went into further detail in my research on materials, I found out that the best wood to use was either plywood or MDF, because they both can be used for good finishing and drilling in bolts, nuts and screws. • Acrylic would be a better option than other sort of plastics or even metals, because they require more effort and machinery • Bolts and nuts should be reduced as possible as they can fracture the material or component • LED is the best option as it was the major choice in my questionnaire and it has the most advantages Ergonomics • The average size of a human is between 2.75-2.49 inches, that’s how big the on and off button should be Cost • After my client interview, he/she was willing to pay 60 pounds for my product, which covers my cost and gives me a 20% profit Environment • My LED lighting should release the least possible waste energy (heat) • I should be as efficient as I can be when consuming my resources at hand. • I found out that the product must be as efficient as possible using up less energy, not wasting any resources and not pollute the atmosphere through emitting toxic gases Manufacturing • Try my best to impose as many techniques as possible such as vacuum forming, 3D printing, CAD/CAM, Laser Cutting, Sanding machine, Band Saw • Must use more finishing techniques to clear things such as bird and rough edges • It should be simple and efficient to assemble and disassemble the lamp
Initial Ideas/Design Analysis
Inspiration from mood board Used plywood to bring the look of the satellite panels, possible engraving can be done on the edges to help it aesthetically Sphere was made by using translucent acrylic, it was an idea to go for colored acrylic, but I had to put a LED light inside the sphere so that it would disperse the yellow light. Used dowel joint to form the panel-inspired wood pieces into the sphere, they can also be used to carry the whole lamp, making it portable and also provide it the stability of staying still on any position you put it in. I created the sphere in 2 semi circles and joined them together, but they both had to be hollow, so I used the vacuum former to make it work Inspiration basically came from a moving satellite, but because I also had the Sci-Fi theme, I put a sphere in the middle to make it look like a moving scanning probe. 1 Inspiration from mood board Formed 2 circular based pyramids and joined them together, to make them look like a an hour glass, top part will hold a red LED light (due to the questionnaire) and the bottom part with blue. They are joined together as a bottle cap is joined to a bottle. It helps in its disassembly if you require to change your LED The hour glass inspired lamp will then be joined together with a cuboid which is made using plywood, and the pieces joined together using butt joints. The hour glass lamp will sit on the cuboid and will be connected using a dowel joint, and the wires will then pass through for the LED light in to the battery slot to make it functional The on and off button which is connected to the battery slot inside the cuboid, obviously there are screws above the switch to open the flab and change the battery if needed. The cuboid which is the base of the lamp, providing it the stability it needs to stand still, is made using 6 pieces of plywood, all connected using wood glue. However the right end of the cuboid was joined using screws or hinges, to be able to open it and make changes in the battery. Inspiration basically came a photo taken by the Hubble telescope which reimages a picture of an hour glass 2 I used the 3D Printing machine to make 2 semi-circles and then joined them together using dowel joints, it was made using acrylic. The cuboid was made using MDF, 4 pieces were cut out in certain dimensions (through trial and error methods) and then were butt jointed together using nuts and screws, so it would help in disassembly. The wires will be going down through this into the base were the battery socket is placed, its colored black due to the majority of votes from my target audience This was actually made using 2D design, I made the dimension and then using CAD/CAM designed it on a software, and then used the laser cutter to cut it out, could be colored acrylic or thin wood, this is basically for the battery socket and has the wires go into it Inspiration from mood board Inspiration basically came from a hovering space ship shaped like a tower, so the sphere on the top represents theme, and the bottom bases represent its mechanism . 3 I used the 3D Printing machine to make 2 semi-circles and then I joined using an either, mortise or a tennon joint, which suits it the best The ring around had to be attached using dowel joints, we had to poles made from any soft wood sticking out which we then connected with the ring around the globe, it just makes it easier for assembly and disassembly, because not 1 screw or bolt is required For this I will be using the mains as the power source, because it is difficult to fit in a battery socket, and will have a on and off button on the bottom Inspiration from mood board Inspiration basically came a photo taken from outer space by a telescope, it shows a gas ring around the spherical planet, this is what I tried to replicate 4 Size Length: 25cm Width: 10cm Size Length: 10cm Width: 20cm Size Length: 25cm Width: 10cm Size Length: 15cm Width: 20cm
3 spheres made from acrylic, so technically I had to manufacture 6 semi-circle which were hollow from within, and then joined them together using tennon joints Method 1 I either take a long piece of MDF which has a width of about 25-30 cm, spray paint it blue, and then use a band saw to cut out the curves which are required. Method 2 I take a long MDF piece, around 25-30 cm and place it in the 3D printed and use CAD/CAM to get my product manufactured Inspiration from mood board Inspiration basically came from a microwave background radiation going through a planet with a gas ring and electro magnetic ring around it I will be using the mains as the energy source (due to the questionnaire), so it will not require the wooden base to be opened in any way. However, the spheres may have to be opened now and then to change the color of LED light (originally YELLOW) or to actually change the light because its gone bad Size Length: 10cm Width: 30cm 5 I will use a coping saw to cut and shape out the acrylic tops and bottoms. I could either do that, or make separate pieces through CAD/CAM and join them together.. The battery socket is in the top red portion, with a black switch, brings a hint of dark matter from the space. The middle cylinder I might have to buy ready made, due to the lack of resources and equipment in you school., Unless, I decide to manufacture the cylinder in a 3D printer, the issue would be how to make it hollow from the middle, which I might have to do by hand, which could damage the product. It will have a fluorescent light inside it, which will be a yellow color. The top and bottom open up like bottle cap making it easier to replace the light The color scheme Red, Yellow and a hint of black was inspired through an image from my moldboard and the questionnaire where yellow and red were rated as one of the highest Size Length: 25cm Width: 5-10cm Inspiration from mood board Inspiration basically came from a Higher ranked droid in Star Wars ® which gave me the idea. The height was basically inspired by it and it have a battery as its source made it look as portable as a droid. 6 The sphere was manufactured using vacuum former, 2 hollow semi circles were made and joined together either using tennon joints or basic slots. 2 cuboids of MDF was taken and manufactured in a way to provide support for the globe, with the blue LED light. The front face edges were manufactured using belt sander, and were sanded until a 45 degree angle. They are then slotted in to the sides of the globes. These will consist of my battery power, and the on and off switch. I will use adhesive paint sprayers to coat the woods red and black due to my audience voting it at the top. Inspiration from mood board Inspiration came from a space ship shaped in a glass globe with 2 pointy sticks pointing out of it, I used the design to support by globe. Size Length: 5-10cm Width: 20cm 7 I will be manufacturing 4 mini spheres using 3D cutter made from plastic and the larger sphere on top will be manufactured in to 2 hollow semi circles and connected together using a joint. They will all consist of Blue LED lights The base is made from MDF with a length of 10 cm and diameter of 10 cm, this was produced using laser cutter, through CAD/CAM. The long cuboid in the middle is the place where the battery is stored and the wires travel through, made from Plywood. The 4 other 90 degree arms are made from acrylic pieces joined together, and joined into the large Cuboid using joints, and the mini spheres are attached to their tops, they will also be BLUE LED LIGHTS. Inspiration from mood board Inspiration came from a space ship with held more that one heads, in different places, the cuboid and sphere were the highest vote attained in my questionnaires, so they had to be imposed Size Length: 25cm Width: 5-10cm 8
Initial ideas specification analysis/Ranking/Match
Sketch Sketch 1 Sketch 2 Sketch 3 Sketch 4 Sketch 5 Sketch 6 Sketch 7 Sketch 8 Brief Description Grey and Yellow one of the colors picked by majority of the audience Consists of a sphere which was voted top in my questionnaire. A satellite-space ship inspired lamp is for creative people, the colors grey and black bring it towards more Sci-fi and space theme relation how nothing has a color in space, inspired from the movie Star Wars(r0 Shaped as a sand clock Slotted on to a cuboid wooden base Consists of blue and red LED lights Very classy and old type look, makes the elderly feel nostalgic. The cuboid is what brings the simplicity in it altogether, having a complex designed and manufactured shape over a simplebasic shape makes it unique Base is red colored with the middle cuboid blackand the top globe translucent but containing a Yellow LED light which provide Yellow light Contains a sphere in top which represents space and planets A towering building representing the building in the republican from the movie star Wars® Contains a sphere in the middle as the disperserof light. The bulb will produce yellow light as stated in the initialideas, due to majority of the vote to yellow Contains a Blue ring across it which contains mini LED lights (Blue) Very basic object and shapes used to make a complex idea, whichattracts the consumer The base of the lamp was colored blue due to majority of votes considering blue to be a highly wanted color The curvy base is inspired by a strand of DNA found in the vast skies of space The spheres represent Civilized planets with yellow/greenlightings Contains a cylinder in the middle with 2 trapezium based pyramids on top. The cylinder has a yellow color due to majority of votes and the trapeziums are red, I was told that the combination of yellow and red is very appealing Color schemerelating to a droid from the movie Star Wars® A sphere was induced into the product which ticks of having a sphere in the product from the specification. Contains the Blue LED light due to the majority of people coting for the Blue color in their questionnaire. Having slim wing on the side of it brings the theme of aliens space ship. Contains a mixture a color which is attractive to the consumer, brown to give it a wooden base look, blue painted tower made from plywood, with 4 arms sticking out holding4 spheres with yellow lights as requested in the questionnaire The largest sphere in the middlewhich is also yellow color whichincreases the radius of the light dispersion. Aesthetics 6/10 5/10 7/10 7/10 7/10 6/10 5/10 9/10 It should be affordable for parents and not to expensive to prevent maximization of profit Did not have a large cost of production Should be cheap and affordable to teens and parents. Had a high production cost which causes an inflation the price of the lamp compared to the other lamps in the market Not too expensive but not very cheap Suppliers would request 20% more of the cost Little bit expensive Due to extensive care and methods of production Difficult to manufacture and requires a lot of fixed cost, which is included in the price Has a reasonable price compared to its cost The producers are only looking to have 20% profit, which would be a8 pounds more than the production cost, which would be around 48 pounds Cheap and affordable. Production cost is not very high, and the suppliers rare willing to only add 10% profit for them self, taking the products to price of 40 pounds. Cheap and affordable Has a very small productioncost, and the producers have this being sold as a minor product, wo they do not require high percentage profit but only about %, which would be about 25 pounds Cheap and affordable The production cost is very low and looking at the versatility of the lamp only 10% profit added on is a fairly reasonably price, making the it 55 pounds Cost 8/10 2/10 2/10 3/10 8/10 8/10 8/10 9/10 Ages mainly between 10-20 Consumer interested in more space dominated theme with a hint of Sci-Fi More of a space ship and satellite inspired lamps A satellite and alien space ship combinationis for all Sci-fi and space lovers Teens between 10-20 Old Sci-Fi themed designs such as sand clock Red and blue color scheme lovers More older type Sci-fi for older people into sci-fi More scientific and classy type look Between ages 5-15 Very simplenot attractive to older audience Audiencewho prefer to have longevity than width of the lamp Inspired from the towers in the republicanin Star Wars ® The globe also gives off injection of static electricity for science lovers. Kids between ages 6-10 mostly from rich families Very basic shapes, not appealing to older year groups Client interested in more space than sci-fi More of space centered theme, where inspiration was takenfrom a Hubble telescopeimage and reformed by the hands through production Between ages 10-25 Has a more complicated hint to it making it more appealing to older aged groups. Audienceinterested in space and Sci-fi inspired lamps For audience who like to have a more complicated and modern design to their sci-fi and space themed lamp. Kids between 9-17 Not to complicated, simple button, simpledisassembly etc. The colors scheme is more droids Sci-Fi space type which would suit teenagers of the 21st century Audiencewho are into the longevity of a lamp which allows the light being disperse to cover up larger radius. Kids between 5-10 mostly boys Very simple, teenagers wont relate to it, as they are to old for space ships and ben ten inspiredproducts. Teenagers would find it harder to relate to the theme of Sci-Fi, as they look for more Sci-Fi or space inspired movies. Audiencewith a very basic and simple state of mind, who dislikecomplications and promote simplicity. Between ages 10-20 Perfectly fits my specification due to the versatility in the design of the product. Not to complicatedand not to simple right in the middleattracting a large group of people in that age group. Good use of color scheme from questionnaire. Client 7/10 5/10 3/10 5/10 8/10 7/10 3/10 9/10 Doesn’t require much energy to manufacture Its repairs do not require any heavy machinery A lot of trial and error methods were used wasting resources. The light bulb released to much heat waste . Recyclable materialsused. Fewer energy used to produce Not much saw dust was produced which is harmful to the environment No melting the plastic or molding metal. A lot of trial and error methods were used wasting resources. Recyclable materialsused. But uses electricity so has carbon impact Production of it releases a lot of fume in to the atmosphere Sawdust very dangerous to human health when manufacturing wood A lot of trial and error methods were used wasting resources. Not environmentally friendly. Requires intensive capital labor (machinery) Whichproduces fumes such as CO2, CO etc. whichall contribute to global warming The light bulb is an inefficient bulb releasing50% heat in to the atmosphere A lot of trial and error methods were used wasting resources. The base wood goes through a whole methods of cutting releasingexcessive saw dust damaging to the human environment. How ever not much energy is need to manufacture the mini 3 spheres. The light bulbs are energy savers which makeit more efficient reducing %age of heat being produced from the lamp A lot of plastic was used generating a lot of fumes in to the atmosphere contributing to global warming The LED light is of bad quality (cheap) still has a high percentage of its energy yield turning into waste heat energy The plastic heated to make the mold of a cylinderwas done through trail and error wasting pieces of plastic. Has no recyclable materials, and the production of it creates and damages the environment The manufacturing of it contains the use of heavy intensive labor whichrequires a lot electricalenergy releasing a lot of waste energy to the atmosphere contributing to global warming. A lot unhealthy toxic fumes are generated Made from thermos plastic acrylic which can be heated an reuse again in other manufacturing processesfor different products in different markets. The wood being used is MDF which is recycled from the saw dust being smashed together. Increased the productivity yield 10 99%, to make use of every single resource used. Environment 5/10 7/10 4/10 1/10 8/10 5/10 4/10 10/10 A few sharp bird edges and the globe could most probably over heat due to lack of protection Can easily fall to the ground due to lack of stability and shatter to pieces. Or could have splinters from the wood everywhere No sharp edges or small parts. Edges are finely sanded Wires willbe exposed so must be careful Easily exposable to water, which cancause short circuit. No sharp edges. Not to heavy All vertices of cuboid while be sanded into a curve Made acrylic does not hold heavy components. The base had sharp edges which could have been dangerous to underage siblings in a family. No sharp edges or small parts. Releasesa sufficient amount of heat energy as waste (50%) Very unstable and can collapse to ground shattering into piece The ring is a very sharp object and can cause cuts and injuries to consumer. Has a few edges but can be easilyfiled or sanded off using a filer or sand paper with different surfaces for different finishes The lightingis an energy saving bulb which makes it more efficient reducing chances of skin burn, The 3 bulbs are heavily exposed which could cause over heating No smallparts Contains many vertices, which can be dangerous for younger category of the clients. Very tall and can fall easily and shatter into pieces which would make it difficult for people to actually Has a few edges on the wing based wooden pieces, very sharp and can harm consumer The globe is ratio wise bigger than the wings, which increasesthe probability of it dropping to the ground and hurting the consumer. The LDR light can over heat catching fire Contains many sharp edges but can be filed and sanded through sand paper, filer or even the belt sander to provide good finish and prevent any injuries to the consumer. The spheres are perfectly attached to their bases through certain joints The arms provide it further stability preventing it from the ground in a split second. Safety 4/10 8/10 8/10 2/10 8/10 6/10 5/10 9/10 10cm x 20 cm Suitable size for a satellite inspiredlamp 25 cm x 10 cm Depending on its components, the size is perfect 25cm X 5cm Length is too long for teenagers to be careful with 15cm x 25 cm Suitable and balanced height for a sphere-globe inspired lamp 10 cm X 30 cm Looking at the shape of it, the size is at its most suitable 25 cm X 10 cm Due to its towering body, the width length is comparatively proportionalto the length it has, giving it stability 10 cm X 25 cm Ratio wise the size is not suitable, and will create difficultiesin manufacturing 25 cm X 15 cm Perfect size depending on the retractable arms on around the cuboid provide further stability. Size 7/10 8/10 5/10 7/10 9/10 9/10 4/10 9/10 Must provide efficient light for the buyer Should be able to stand easilydue to the wings provided. Easily portable The Sphere increases the dispersion radius of light The wings also hold the battery socket and the witch to turn the lamp on or off. Provides a mixture of lights, not suitable for teens studying in the nights Provides sufficient light for other uses The base provides stability for the sand clock inspired acrylic lamp The right flap of the base, is attached through hinges which is detachable to change the battery socket. The slot underneath the sand glass inspiredlamp is made to be sat above. Towering body to disperse the light to further areas The bottom wooden base gives it the stability and position it requires It has flappingsides to place the battery socket in and to connect the switch to. The right flap of the long cuboid is joined through hinges and detachable anytime to change the battery source Easily portable due its balanced size and shape The ring around it provides it with the minimum stability required to stand still in its designated position allocated to it by the consumer. 2 semi circles are made to make it easier for disassemblyand changing the light source The ring being attached through 2 rods to the sphere shows a change in the LED lights when a certain mod is applied to it. 3 spheres provide more sufficient lights for a dark room. The curvy shaped base is there to support the 3 sphere to disperse at their best possible radius. The right end of the base contains hinges and opens up to change battery The small clips on the spheres are there to make it easierto open them and change the bulb, the switch turns on and off It having small width provides easy accessibility and easily portable. The top trapezium can be opened as inspired by the bottle cap and the bottle itself The black switch on the top trapezium is there to turn the lamp on or off. The cylinder holds the Yellow LED light The top also has the mains connected it, which continuesinto the cylinder The wings are there to provide minimalsupport and stability to the sphere so that it doesn’t always completely fall down and damage itself. The button on the switch is connected to wire going through the globe and coming from behind it connecting to the mains as it is the power source of the lamp. The sphere was induced into the product due to its increasing in portability or accessibility of the product. The larger numberof spheres attached into one condensed area increases the radius of light dispersion, creating efficient light for the 10-20 year old to study. The base on the bottom hold the battery socket or mains which ever seems suitable at the time of production. The towering cuboid in the middle is there for the retractable arms. The arms are movable concentratinglight on certain objects, places of people Function 8/10 3/10 8/10 9/10 8/10 8/10 6/10 9/10 Sphere is made from 2 separate pieces of acrylics Joined together using joints or glue The wings are made from plywood manufactured using tennon saw or band saw Dowelljoints had to manufactured using had craft wood to make it easier for joining Requires a lot of material Difficult to join an acrylic product to a wooden base Base made from Plywood The top sand glass is made from 2 different colored acrylic using coping saw to manufacture and CAD/CAM to manufacture the base The right flap attached through hinges and openable for disassemblyand assembly Basic wood and Plastic was used Globe/Sphere was manufactured using3D printer to create 2 hollow semi circles and then joined together using doweljoints The base was manufactured usinga tennon saw to cut out the wood and the same for the towering cuboid which is joined through 6 pieces using wood glue. The base was very thin and made from MDF so smacking in nails, and bolts would do not favor, so attention had to given. Only Acrylic (plastic)was used in the manufacturing of this product 2 Semi circles were manufactured using vacuum former and joined togetherusing butt, tennon or mortise joints to make it easier for assemblyand disassembly. Ring was made using CAD/CAM through Laser cutter then heated and molded into ta oval shape around the sphere Joiningthe ring with the sphere had to be done using 2 rods connecting it from exactly opposite sides Wood (MDF) and plastic (Acrylic) were used The spheres were made suing 3D printer and joined together using joints, and were given clip type buttons which when adjusted would detach the spheres and expose the LED light, ready to be changed The base was made mostly using CAD/CAM and laser cutter but some parts were made using tennon saw and glues together with the rest of the pieces to make th inspired shape.. The materials acrylics and Plywood were mainlyused The cylinder was made using a2D rectangularpiece of acrylic heated and molded round into a cylinder with open faces We then manufactured the wooden trapezium using either 3D printer, CAD/CAM laser cutter or just basic tennon saw and belt saw. The bottle turning pathway was made using computer aided design and completed of using D printer The sphere made using vacuum former and 3D printer, 1 hollow semi circles made using 3D printer and the other one was made through the vacuum former to create separate joints and join them up together to complete the 3D shape. Basically made from Acrylics and plywood, as they are the easiest to manufacture and produce and cheap in comparability to others. Had to create a certain position for the bulb to fit in the sphere, so a drilling machine was used to mark a position Mini sphere manufactured using 3D printer after designing on CAD/CAM and the large sphere on top was manufactured using the vacuum former which makes it efficient. The base was made form MDF and the cuboid tower was made through manufacturing of plywood cut through laser cutter after being designed on CAD/CAM and joined eitherusing glue or joints. So are the arms which contains hinges making it retractable and movable to any position required, to concentrate in any position Materials/Manu facturing 8/10 8/10 9/10 5/10 9/10 9/10 7/10 10/10
Development of sketch designs.
Sketch 5 Sketch 8 My initial design basically came from one of he pictures/images in the mood board. This is what was the first thing that came to my mind when looking at the picture, and I will now further develop it using focusing on certain designing aspects of the design Inspiration from mood board This was the image where I got my inspiration, its what gave me the idea of actually making the product in such a way Rather than having 3 under tunnels on my product, and 3 light sources in 3 spheres, I decided to have one upper tunnel, where 2 spheres can be condensed together with LED lights The Spheres will be a foster white acrylic with 2 LED light sources, with the body of the lamp made from Plywood either through CAD/CAM and laser cutter or just manufacture it using a band saw and a tenon saw, gluing them together The spheres will be slotted in together into the base of the lamp, either using dowel joints or just another form of connection because through my research I had found out that dowel joints would be perfect for joining components.. There will be partition on top of the bottom circle to prevent it from movie, but will be retractable to open and change the LED light After the development of the design I had found out that I would be using up less resource, which per y specification is a good idea, I have to make it as eco friendly as possible, and rather then using 3 spheres with 3 LED light sources, I would just use 2 of them condensed in one are to reduce the waste heat energy being produced and emitted into the atmosphere Environment Wing function The wings on the side allow the lamp to be set or placed in 3 different position, this improves its adaptability Cost The cost of it automatically reduces due to the les consumption in energy and resources, falling from 48 to 35 pounds Inspiration from mood board Inspiration came from a space ship with held more that one heads, in different places, the cuboid and sphere were the highest vote attained in my questionnaires, so they had to be imposed My initial idea came from one of the pictures in my mood board. The first sort of inspiration I get from that picture Is what I used to design this lamp, with some obvious changes in its certain aspects such as aesthetics, shape, sizes etc. Through looking back at my color scheme in my questionnaire, it showed how yellow and black were one of the top rated colors alongside blue, so a color of scheme of at least 2-3 colors was also requested by my client, which is why I took this step in its developments. Also the color scheme blue and red was to old Color Scheme In my initial design I had 5 spheres (1 large sphere, 4 small spheres), but due to the fact in my research and client interview, it had to be as efficient and eco friendly as possible, so to reduce such heat waste energy, I decided to deduct the number of light sources by 2, but they still consist the LED lights (Yellow) as the were rated highly in my questionnaire Base size In my initial design, the base had a smaller length or thickness, but after some further research on stability of products, I found out the base must provide the main stability and stating the fact the top parts are heavy, the base must be able to go under such pressure. The color was changed due to the review of my client, he stated that he wanted only 2 different colors on the body, rather than 3, and through my questionnaire these colors made the perfect scheme Environment The two arms are there to provide sufficient stability and improve the dispersion of light, as quality of light was to be taken in certain thought from the interview with my clients. Arm Function Cost My initial design was ought to calculate up to 55 pounds, however, after taking out 2 light sources, , the price drops by 20% to 44 pounds
Model dimensions for developed designs
Sketch 5 Development modeling I used 2D design to sketch the 2 faces of the product inspired from sketch 5. It was a better way to manufacture the lamp model in this way, because it would have been difficult to include the curves of cardboard etc. Minimum space was covered to prevent from wasting cardboard as we had a shortage of resource. Made it more efficient. One of the specifications in the environmental part of the product was for it to be as eco friendly as possible. I had to use the 2D design to make the pieces that would join the 2 faces back to back of each other, to do that I had to get similar measurements, and make sure that were accurate. Length x Width Quantity 2 cm x 5 cm 2 7.6 cm x 5 cm 1 5 cm x 3 cm 4 3 cm x 5 cm 4 13-15 cm x 5 cm 2 I had to work out the dimensions of these pieces in relation to the 2 front and back faces of the lamp, to prevent a clash in sizes. Some of them I was unable to calculate due to certain limitation, so when the 2 faces was laser cut I used a rule to measure certain lengths and widths and used a cutter and a cutting board to manually manufacture some of the pieces.. This is the 3D model sketch of the base of the product with out the spheres, which are identified to be bulbs containing yellow LED lights because that’s what people who voted in my questionnaire wanted I was unable to manufacture the models of sphere through plastic, because firstly we lacked resources and we lacked the equipment of turning cardboard into sphere, so to represent the sphere I laser cut through designing on 2D design and added slots to them of 3.5cm x 1 cm, and will then be slotted together and placed into the base which is made from cardboard as well representing a wood base. The front faces I had cut out using a laser cutter, but a few of the small pieces I had to cut using a cutter, which I did using the same sheet of card board to make it as efficient as possible, and then I glued it together in the smallest time possible, as I had used only one stick of hot glue gun, so prevent heat energy from being released Making the Model
Sketch 8 Development modeling Length x Width Quantity 2 cm x 8 cm 4 2 cm x 2 cm 2 4 cm x 2 cm 8 1.5 cm x 2 cm 8 1.5 cm x 1.5 cm 2 2 cm x 19 cm 1 Circle 6 cm x 6cm 2 TOTAL 27 I had to look at the developed design and think of which pieces and what quantity will I need them in. I also had to figure out the dimensions for the pieces, and they had to be in all relation to each other, so there is not even a single clash in sizes. All these dimensions were put into a CAD/CAM software and drawn through software These are the dimensions and quantities of the pieces needed to make the model/prototype. There were a total of 27 pieces consisting of pieces with different dimension, all these pieces were manufactured through cardboard, as we did not have enough plastic to make a more stable or better quality model Manufacturing the Pieces The pieces were manufactured through a CAD/CAM machine, commonly known as the laser cutter. You must input the density and mass of the material which is cardboard, and so it starts to cut the pieces through a laser heating certain areas of the card board. To save resources and make it as efficient as possible, as it was one of the environmental aspects requested by client, we brought all the pieces very close to each other, to waste as least as possible I first made the base, by curling up the long rectangular piece and stuck the 2 circles back and forth using the glue gun. I then made the long cuboid body, by joining four pieces together, and then did the same for the arms, which were then all connected using the hot glue gun. For the 2 mini spheres and 1 large spheres, I had to represent them through a candle and 2 small bottle caps, because I had lacked resources to actually make a model for a sphere, I decided to represent them through other objects, after all it is a model The Model Making Method Main large Bulb represented by Mini candle 2 mini bulb represented by 2 bottle caps
Strengths and Weaknesses of the models Model Of Sketch 5 Strengths Weaknesses The sizes were a perfect fit, all the pieces came together due to the accuracy of the measurements I was unable to manufacture the curved cardboard piece to go inside the body It was manufactured through pieces being cut in the laser cutter, making it very easy. Manufacturing the sphere through cardboard, and we did not posses enough plastic either 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 property in 2D design (software), it resembled exactly like the drawing. The glue gun had good effect, however it had unwanted strings of hard glue everywhere, which brought a weak aesthetic aspect to its part Lack of colors made the model look aesthetically weak Model Of Sketch 8 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 Using the bottle cap and candle as models of sphere bulbs was not the best of ideas, as it brought the aesthetics part of it to its weaker side The base was really stable, because of the extreme flatness in the circles 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
Final Design
The base will be manufactured by using MDF. I will be using a tennon saw to cut out the shape or using the band saw is also an option, as I had found out through my research that they would be the best in cutting wood into different shapes, woods such as MDF, Plywood. The bulbs will be made using clear acrylic and will be manufactured using either a 3D printer or a vacuum former, as I found out through my research they were the best machines to make the spheres. I will make 2 semi hollow spheres and join them either using an adhesive or a wood joint such as tennon, mortise or dowel classified to be the best at the job I will be using the laser cutter to make the front and back face of the body as a whole, and then cut out the other pieces separately, and join it together using a wood adhesive, As per the results on my questionnaire, I had found out people preferred to have a lamp with a battery as its energy source rather than the house mains, so the switch is connected to the batter which is connected to wires coming from the bulbs through the whole body of the product. Why is this the best model • Firstly, the base is a flat circle of MDF, which shows how strong and stable it is • 3 spheres containing LED lights are spread out in the best of positions to disperse the light as far as possible, as per the specification • The design is a merger or a rebirth of the 2 developed models I had made through 2 of my initial designs • This design embodies the theme of Sci-Fi and Space perfectly. How does this portray the theme? The base representing a flying saucer which is part of a Sci-Fi aspect or feature, with the space ship inspired body, space is resembled through it, and in the end with the 3 bulbs on the product, it just puts together the 2 similar theme as the cherry on top. Using the Questionnaire Green = Achieved Orange = Moderate achievement Red = Failed • The LED lights • Using MDF or Plywood • Sci-Fi and Space theme • Battery as an energy source • Have any of the 4 colors, Red, Black, Yellow or Green (3 colors must consist in the product, as per specification) • Most important aspect (Aesthetics) off the charts and visually pleasing • Have it linked to the Star Wars® movie (basic inspiration) • Contained Spheres Environment/Sustainability • LED light being used as light source is a very eco friendly idea, as it does not release any sort of waste energy dangerous to consumer such as heat • MDF can manufactured using human force, and does not require the laser cutter to be used and use up electricity, and its easily recyclable. • Along with MDF, Acrylic can be recycled easily, and can be disposed of easily due it not being glass and harmful to the nature or the consumer himself Inspiration for the final design (from mood board, sketches and development)
Parts assembly X2 Orthographic Drawing and Components of Product
Model of the final design The bulbs will be made using clear acrylic and will be manufactured using either a 3D printer or a vacuum former, as I found out through my research they were the best machines to make the spheres. I will make 2 semi hollow spheres and join them either using an adhesive or a wood joint such as tennon, mortise or dowel classified to be the best at the job I had used the table as its base so that I would not have had to waste anymore resources to make the base, as it could have just been easily substituted for the time being, making the process of my product production a whole lot more efficient, due to it being the request of my client. The body was made through using the foam material, and was sliced into shape through a band saw, I first got rough and raw measurements and then I drew the shape to size on a large rectangular piece of foam, and then I used the help of my teacher to cut out the shape of the body which replicated the acyclic body The spheres were made in parts, firstly I manufactured 6 2D circles through the laser cutter, with slots in them, to connect, and then I placed cut out skin tights over them to keep them in place, and give it a sphere looking aspect This is the 3D Auto-Desk inventor 2015 model, I used my past experience with this software to plan out every single part of the lamp and assemble them together and give it a color scheme. Autodesk inventor 3D model (CAD) Strengths Weaknesses • The band saw was able to craft a very accurate and perfect body from the foam • The sphere-representing objects don’t really weigh much on its aesthetics aspect • The slots in the circles did well to hold together. The perfect weights allowed equal momentum on each arm. • The arms of the body were made too big, and it base was smaller, so it would sometimes become unstable and collapse MODIFICATIONS TO FINAL PRODUCT (big changes) • I would have to keep in mind the scale ratio of the base and the body, so that it does not fall off all the time • I would stuff the tights-spheres with some cotton to bring out a more perfect 3D sphere look • Add more colors into the model to give it a better aesthetic aspect. • I could use some sort of cylinder with a controlled height to represent the base, which I could not manufacture due to lack of resources • I also realised the sphere-bulbs will not be sufficient in producing light, so I have decided to change the body material from wood to acrylic and place LED lights in it as well
M.E.S.S Development I will be using a lot of acrylic in this, so it actually makes my product really recyclable, because it can be melted and molded into different and new shapes and products Recycle Repair On the bottom of the base, there is a flap which opens and allows the consumer or the assembler to repair the battery socket or mains (which ever is being used) the spheres are held together by slots, so they can be opened and the LED lights can be repaired Reuse I could try and use the acrylic and woods from an old disassembled product, which would only make my product more efficient and environmental friendly, because there resources are not finite, and we lack the supplies. I could have tried and used glass for the spheres to give it strength in its function aspect, however I did not have the material (very opulent) and did not have the equipment to manufacture it. I could also have had used plywood, however it would not provide the same aesthetics furthermore, its very porous and can soak up water increasing density and mass of the product Rethink Reduce I would try and use the materials my colleagues have already used for manufacturing, as long as I make most of the remaining resources, and not wasting any, it will be as efficient in its production as possible Refuse I have used MDF rather than using mahogany or oak tree, because oak and mahogany are to difficult to manufacture and require immense energy, they are also a very rare and expensive resource to purchase, so this makes my product as efficient as possible Making sure my product takes the moral, environmental, social and sustainability issues as it is very important that it suffices all of these aspects I am going to use the 6 R’s to annotate my product. Introduction Sustainability? • My finished product is considered to be sustainable because the place where I bought my wood from is a sustainable resource, every time they chop wood off, they replant a tree • It is also sustainable because I used acrylic and MDF parts which had already been used by old disassembled products • My product is not sustainable because I used a lot of electrical CAM machines, which require heavy energy which is environmental damaging, which is against my specification • The paint I used cannot be trusted because it could be worn off through heat. • I could try and apply a paint adhesive which has high resistance to heat and radiation • Use only those machines which use less energy, and try to minimize their use in the making of my product Sometimes some products do not always fit in a market due to their cultural, moral or religious reasons. For example, my product has a Sci-Fi theme to it, which a lot of parents regard as the cause of brainwashing for teens and kids these days, which is why I could possibly have to face legal actions including prosecution. I would then possible have to remove the black color as well, as it portrays a theme of ‘gothics’ which is against or neglected by many people in the social community. Moral and cultural issues • How is it sustainable? • How is it not sustainable? • How could it possibly be more sustainable?
Testing and Development In my first attempt to make the shape which will assist in the dispersion of the light, I had tried to make a sphere. To do that I created a drawing using my dimensions and then placed in the CNC Machine, which 3D printed the 4 pieces of MDF I had beforehand glued together using wood glue. After the 3D semi sphere had been printed, I found an issue with it, a part of it was damaged during the removal from the machine, which forced me to apply clay on to the damaged area to retain its spherical shape. After I had repaired the semi sphere, I placed it in the vacuum former, which was preheated having placed the HIPS. Once I got the shape of the semi sphere onto the HIPS, I had to remove the external edges and try it improve it aesthetically using the machine. However, in the end the process had not produced an aesthetically pleasing result, which made me disregard the manufactured, and I had given it to one of my colleague, as one of my criteria points is to be environmentally friendly. Method 1 (CNC/Vacuum former) Method 2 (Autodesk Inventor/3D Printer) In my second test method I used the Autodesk Inventor software to generate a semi sphere hollow from the inside with stars on the skeleton of the body in order to give it a aesthetical visual. After I did that I saved it as an .STL file. I then used a software called CubeX, where I imported the file and then printed out the 3D object, however in my first attempt I had gotten the dimensions incorrect, so I had decided to re-attempt the method, however the 3D printing machine had broken down for good, and our school was unable to repair the machine or provide me the color of my choice. So I had turned down this method as a tried, tested and failed! In my 3rd methods, I decided to try a different idea, keeping in mind that my client would accept either a sphere or a cuboid, I decided to fulfill that request. I used 2D design to draw pieces for the cuboid, with finger joints to certain dimensions, which allowed it to fit together. I then got them manufactured through the Laser cutter, and after that I used the solvent cement to glue the pieces together, after I placed the LED light within the holder I had drawn for it. This method prevailed because not only was it aesthetically pleasing but was also very technical and efficient Method 3 (Laser Cutter/Solvent Cement)
Making Diary (the body) To start of the making of my product, I used the machine which is known as the ‘circular saw’, and I used it to cut out 4 large pieces of MDFs with dimensions of 20 cm x 20 cm. I had to use safety precautions such as a plastic stick to move the pieces onwards, as using my hands would be a risk to my safety aspects of manufacturing this product. The reason I used a circular saw was because the MDF piece was large to handle with either a band saw or even a tenon saw, so to make the quality of the pieces was on top, I had to make this decision. After the manufacturing of the 4 pieces through a large MDF slab. I had to make 2 thicker MDF pieces because the single piece had thickness of 15 mm, which is to small, I needed a thickness of the body to be 6 cm, so if I can have 15mm pieces (x4) I can have 60mm of MDF, which is 6 cm, so I stuck two pieces together to make 2 30mm thick MDF pieces, I did this using wood glue, and made sure that I didn’t drop any glue anywhere else on the body or else it would give it a bad aesthetic view, to let the glue dry I had to attach 2 large size G-clamps and a medium sized G-clamp along with it placed in a vice on a table, this was done to make sure that the pieces did not move around changing the shape of the pieces from it required pieces, this was done to make sure the quality of pieces was on top I then took my prototype and placed it on the 2 thickened MDF pieces and drew out the outline shape of the product, to make it environmentally friendly and keeping the 6 R’s in my mind, I cut out the shape using the end of the pieces through a band saw, I used a band saw because it was the only thing strong enough for a piece like that which is holding dried wood glue, using a tenon saw would take me forever and would require more work done., I had to cut it out by using different angles to make sure the saw doesn’t go off lines. I had to makes sure to wear goggles and keep my fingers away from the saw. You can now see that I have cut out 2 30mm thick pieces of MDF like my template, this makes my quality as accurate a possible, because the template I used was my final design prototype, which was made through original dimension, you can now see the 2 MDF parts are equal and similar in sizes, and I will now sand them to ultimately glue them together using G-clamps, Vices and wood glue…….BUT FIRST SANDING! After I had my 2 pieces of thickness 30 mm cut out, I had to make sure that they both were symmetric to each other, to do that I had to make use of the belt sander, to use the belt sander I had to hold the piece on to the plate of the belt sander and push it on the belt, manoeuvring it along the process, for safety reason I had to place my had far away because the belt can cause friction on skin creating burns, and as well as that I had to use goggles to keep my eyes safe from the saw dust. Taking intervals was important to prevent excess inhaling of sawdust. 1 2 3 4 5 • Specification related • Machines and equipment's • Other methods and things
Making Diary The belt sander brought some limitation which were that sometimes it was unable to reach certain areas due to the shape of the product, because of that I had to sand the remaining areas manually using my own physicality, took some time but got the job done. I had to tightly place it on the table vice and then sand it. I used a technique which made it a whole lot easier for me to sand and faster, I took a block of wood and wrapped some sand paper around it, and then I used it as a lever to sand the faces of the part, preventing any curves from being made which were not required. I had to take certain safety precautions such as making sure I don’t rub my fingers on the sand paper or cut splinters. I also had to take intervals to make sure I don’t inhale too much saw dust. After finishing I also cleaned up the whole area making sure that I leave no saw dust on the floor because that would be against my specification which says to be environment friendly. 6 7 8 After sanding down the whole body of the lamp, I had to begin painting it as a whole. To do that I had to make sure that the MDF was not soaking in any of the spray paint, in order to prevent that from happening I sprayed it with prima, which was a white coloured spray. I then let it dry for about 20-25 minutes, only to return and begin the actual painting. Before hand, I tested out how thick I wanted the paint coating to be on the wood, so I do not ruin it. I did a hit and trial method on multiple recyclable pieces of wood, until I found a perfect thickness. I then applied that thickness on to the body of my lamp. The thing about the paint I had used was that it was paint + prima, which gave it a more aesthetically pleasing view. I made sure that I did not inhale any of the paint and did it outside keeping in mind how toxic excess inhaling of spray paint can be. The second part of my lamp was the base. It was important that it was a base which would provide my lamp with the stability (as per my specification) it requires keeping in mind the excessive weight placed on the wings of my lamp body. So to do that, I went onto the Autodesk Inventor software and drew a 3D cylinder with a diameter of 23 cm and a depth 30mm. After it was drawn, I consulted with my teacher if it had was appropriate dimensions for production. After his nod, 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 15mm MDF I had previously glued together (wood glue) in to the machine. I then begun the process which took around 10-20 minutes. After it finished cutting, I had to manually complete it using the band saw machine, I wore glasses while carrying this out as well as under supervision. This is the bottom face, the cut passage from center through extrusion is a passage for the wires
9 After I had completed the cutting and the sanding of the base, I then moved on to the its finishing. Firstly, I made a hole through the center of the base using a drill machine, I did that while wearing googles and made sure that the object I was drilling was sitting there firm and steady. Once I had made the hole, I then placed the spackling on to the side of the base, while sanding it down with black sand paper, I then moved on to the painting part of the process. I took the base outside, placed it on an object not touching the ground and spray painted it red, the first coat I performed was left to dry inside, because if I let it dry outside then it becomes sticky, only to apply the 2nd layer of coating after around 20-30 minutes, the paint I used was really efficient because it consisted of prima and paint together. While I was painting I used a pluck to keep my nose closed so I do not inhale the toxins, and I made sure to do it outdoors away from plants and any other human 10 The 3rd object which was a part of my lamp was the object holding the light source. Now as you may know that I had planned to have spherical objects do that role, however due to the limitations such as lack of technology, equipment and others, I was unable to fulfill that part, however in my previous slides I stated the 2 method I had attempted to make spherical objects and how/why I failed. Also stating how the production of the cuboid became more efficient and aesthetically strong. I took this decision because my client had previously stated that he would be willing to accept cuboidal shapes as well, so as per my specification I’m on the right track. I first designed the 6 pieced cuboid on 2D design. 4 pieces for the sides, a top lid and a piece which slots between/inside the shape with a circles cut through as a place for the LED light to sit. I then used the laser cutter to cut the pieces out, the material I used was acrylic, blue color specifically as per my questionnaire, so that the light would be dispersed better, I made sure the suction was turned on, so I would not inhale any toxins 11 After the pieces had been cut, I had to start putting them together. To do that I had to first place together all the pieces and see if the finger joints fit. After my first try, the fit was perfect. I then began to put the pieces together. Piece by piece I glued together using Solvent Cement, a liquid which glues together acrylic/plastic. While I did that, I had to wear gloves, because the solvent was very irritant, and if was poured on my skin, I would have an issue. I poured the liquid into a cup, and used a paint brush to spread the solvent through the edge. Before gluing the lid, I placed the LED light into the cuboid, with its bottom pins facing the lidless end, where it will be connected to the wiring. I did the same and created another cuboid, because I required 2 of light source holding objects. 12 Once all the pieces had been made, wiring had to be done. The 2 live wires had to be joined through welding, while the 2 neutral wires (blue) did the same, and the green wire (earth wire) was together from before, and we then screwed them in to a mains While using the welding tool, I wore gloves to prevent burns also we had a wool mat to cool the metal end down.
13 Once the wiring is done, the next and final part is putting the part together with the wiring connected. First I placed the wiring between the 2 body pieces only the glue them together using wood glue. I then send the wire through the base which places the whole body onto the face of the base, to make sure it stick there, I placed some wood glue underneath the black painted body. I then connected the wirings with the LEDs in the 2 acrylic cuboid, while once again going over the edges of the box with Solvent Cement. Once all of the things were put together, I then decided to plug in the main, but I made sure that I was plugging it in a switch which was turned off, because a short circuit could cause fire, and once I placed it in and turned it on…….. Finished!!!
EVALUATION AGAINST SPECIFICATION/ QUALITY CHECK Function • It should provide sufficient amount of light for reading or studying • It should be portable anywhere around a room • The on and off button must be working flawlessly  The mains switch works great, with the wiring is perfect and strong Aesthetics • My product should follow my Sci-Fi/Space theme  Has a Sci-Fi spaceship look • Lamp should not have any bird edges, or anything that makes it look messy • It must have majority of the colors which were chosen in the questionnaire  3 colors (blue, black and red) highest polls • No rough edges of the wooden base or any dripping paint be visible to the costumer  Well sanded using belt sander and sand paper Safety • It should not have anything pointy sticking out of it, because my product is basically for teenagers, who make harsh decision very quickly • It should be in a state where it doesn't falls of anywhere it is kept, because if it consist of glass, then it will shatter everywhere  The cylinder base makes it very stable Size • As the majority of my clients stated that he/she wanted a height between 30cm – 50cm  My lamp had a height of 45cm • Must consist the shapes which were chosen at a majority between the 50 people such as a sphere or a cuboid Customer • Its mainly for people between the ages of 10-20 (adolescents)  The color and shape is attractive to young aged people • For people who are into the Sci-Fi/Space theme • He should also have interest in mechanics, technology and modern looks  Has wirings and LED light which look like Iron Man’s chest piece Material • As I went into further detail in my research on materials, I found out that the best wood to use was either plywood or MDF, because they both can be used for good finishing and drilling in bolts, nuts and screws. • Acrylic would be a better option than other sort of plastics or even metals, because they require more effort and machinery • Bolts and nuts should be reduced as possible as they can fracture the material or component • LED is the best option as it was the major choice in my questionnaire and it has the most advantages Ergonomics • The average size of a human thumb is between 2.75-2.49 inches, that’s how big the on and off button should be  The mains switch is based off that Cost • After my client interview, he/she was willing to pay 60 pounds for my product, which covers my cost and gives me a 20% profit Environment • My LED lighting should release the least possible waste energy (heat) • I should be as efficient as I can be when consuming my resources at hand. • I found out that the product must be as efficient as possible using up less energy, not wasting any resources and not pollute the atmosphere through emitting toxic gases Manufacturing • Try my best to impose as many techniques as possible such as vacuum forming, 3D printing, CAD/CAM, Laser Cutting, Sanding machine, Band Saw • Must use more finishing techniques to clear things such as bird and rough edges • It should be simple and efficient to assemble and disassemble the lamp  Only 3 pieces are required to be joined, the others have finger joints to make it easy • Achieved  Explained how? • Moderately achieved • Failed
Evaluation- Opinions Where would you place the lamp? Bedroom Living Room Garden 4% 10% 50% 20% 16% How much are you willing to pay? £40 £50 £55 £60 £70 70% 16% 14% What aspect of the lamp is your favorite? Light source holder (cuboid) Body (black) Base (Red) 20% 80% Would you buy the lamp? No Yes 4% 80% 16% What aspects needs improvements? Light souce holder (cuboid) Body (black) Base (Red) 100 % 0% Does the lamp embody the theme? Yes No • The body could be a bit more symmetrical to the other piece of the body. • Another layer of paint would have helped. Popular suggestion Favorite things about the lamp • Embodies the theme • Looks well finished • The design is very simple and easy to assemble • Easily portable • Looks really stable, even thought a design such should be very unstable. How would to improve it? • First thing, I could further sand the body as a whole, to get the better symmetrical shape which was being brought up by the buyer • Also I could put on another layer of the prima + paint I had used.
Modifications • A way to improve on the size would be avoid having aspects of the body so thin, vulnerable to damage. • Try to have a better aspect ratio of sizes between the parts of the lamps Size • I could next time try and actually make prototypes of every single part before actually starting production on the real parts. • Try to be as efficient with the resources (such as paint, acrylic, and wood) as possible Environment • Try and improve the balance in the paint layers applied onto the parts of the lamp • Use an alkaline solution to remove the marks left by the Solvent Cement. Aesthetics • I could have sanded all the edges to make them even more safe for the user. • Rather than acrylic, I could’ve used a metal which would require a lot more force to crack than plastic Safety • A more clear show of the function of the black painted body. • The middle part in the body could have also consisted of a light source to produce even more light Function • I could make is more consumer customizable, like I could have different colored acrylic cuboids, which would disperse different lights. Customer • Instead of acrylic I could have used a metal which is way more strong. • I could use stronger LEDs to have stronger light dispersion Materials
Evaluation- improvements + overcoming problems + Factory Production Factory/Mass production 1. The top acrylic boxes are produced through drawing of the pieces on 2D Design, being produced through laser cutter, so this shows how cheap it can get, because acrylic is not that rare, and is really cheap to buy, so you can but it in a large amount. 2. The base is manufactured through using the CNC Router after it was drawn on Autodesk Inventor, MDF is not that expensive and is very easy to manufacture, also sanding it is also very easy, which means that finishing of the base would not take that long, time and work load efficient. 3. The wiring used in the lamp is very basic, with the red live wires coming from the LEDs are connected together as well as the blue neutral wires while the brown/green earth wires are left separate, basically a structure of a mains mechanics which is cheap and heavily available due to it mass structure. 4. The body is the only thing which can take time, however, having the MDF cut in big bunches will allow more time to be saved, perhaps the cutting may not be as good, but remember that its MDF, which is easily manipulated through sanding machines. 5. The LED lights are in mass production already and are cheap to buy in bunches, keeping in mind that these are the best kind of light source, because they do heat up as much as filament bulbs. 6. This shows that this lamp can be produced at a large scale. On the first layer of the paint I had sprayed, I left it to dry outside underneath the sun, keeping in mind I had used black paint, it heated up, as well as became a bit sticky, so I had to bring it in the air-conditioned room to cool down only to reapply the paint Painting Issue Body Cutting It was really difficult to cut the body of the product, because of its irregular shape, using a band saw to go through such sharp turns was difficult, so to overcome such issue, I had my teacher give me a tutorial by cutting the 1st of the 2 pieces himself, and then I had understood how to do it, my attempt was 99% similar Problem + overcoming the problem

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GCSE Product Design

  • 1.
    Content1. Design brief,Context and Problem 2. Questionnaire 3. Mood board and client profile 4. Existing products analysis 5. Disassembly of a home lamp 6. Basic Components analysis 7. Manufacturing Research 8. Joint research 9. Research summary 10. Specification/Quality control 11. Initial ideas/Design analysis 12. Initial ideas specification analysis/ranking/match 13. Development of sketches 14. Model dimensions for developed designs 15. Sketch 5 development modeling 16. Sketch 8 Development modeling 17. Strengths and weaknesses of the models 18. Final Design 19. Orthographic drawing and components of the product 20. Model of the final design 21. M.E.S.S Development 22. Testing and development/modification in final design 23. Making Diary 24. Evaluation against specification/Quality check 25. Evaluation-Opinions 26. Modification 27. Evaluation- overcoming problems + Mass production Research Development Making Evaluation 3-14 Page Number 3 4 5 6-8 9 10 11 12 13 14 15-17 18-19 20-21 22 23 24 25 26-27 28 29 30 31 32-35 36 37 38 39 15-31 32-35 36-39
  • 2.
    Problem Kids between theages of 10-20 (teenagers) usually study the whole night in either dim light or a lot of light (which is not cost effective), they require personal lamps which are cost effective and not eye damaging Design Brief I am going to design and manufacture a working personal lamp for teenagers who work very hard for their exams in the night times. This lamp will protect their eyes from any further damage and any stress induced by the lights. This should improve their efforts in study and produce much more quality and standardized grades. Design Brief, Context and Problem
  • 3.
    0 2 4 6 8 10 12 14 16 Column1 Red Blue Yellow Black Purple Green White Gray What type oflighting would you prefer? 4% 40% 6% 20% 30% Types of lighting HID LED Halogen fluroscent Energy-saver What aspect of the lamp do feel as vital to its selling? 30% 20% 10% 20% 20% Aspects of a product Asthetics Cost Function Material Others What 3D shape do you like on a lamp? 11% 38% 4% 31% 10% 6% Shapes Tube lines Sphere Cylinder cuboid Irregular 3D shape others 70% 4% 16% 10% Basic inspiration Star Wars® The Guardian Of The Galaxy® Star Trek® Prometheus® What Sci-Fi movie should inspire the main design of the lamp? Mains or battery? 70% 30% Energy source Battery Mains Conclusions from questionnaire data • Black, white and red should be thought being used the most • Aesthetics plays a major role in selling the lamp • LED is preferred over HID, Halogens, Fluorescent and energy saver • My clients prefer a lamp to consist of spherical and/or cuboidal shapes • Star wars® should be the main inspiration base of the lamp • Mains would suite a lamp more than a battery socket • People are willing to 60 pounds for this product Questionnaire
  • 4.
    Client Profile My productwill be on any furniture or lamp store, or even online on websites such as eBay, amazon etc. People between the ages of 10-20 would be interested in my product, mainly fans of top cinema box movies such as Star Wars®, Prometheus®, Star Trek® etc. It gives a theme of Sci- Fi and space. It also shows the correlation between these themes. My client would be someone who is interested in the modern style of certain things as show pieces, and my product is a perfect example of modernization at its best. This lamp would fit perfectly in a teenagers bedroom, which would show his interests and passion. Mood board and client profile
  • 5.
  • 6.
    Aesthetics • A combinationof different shapes • A mixture of 2D and 3D shapes • One certain color to attract certain audience • 2D shape around the globe replicates a gas ring of a planet in out solar system • Orange color to replicate a gas planet • Circular to portray a stereotypical shape for a planet. Client • For people aged from 7-16 years old • Space theme to attract astronomy lovers • Clients who prefer the color orange over the variety of others, due to personal preferences Cost • 100 DHS • Costs of labor and work rate from workers • The cost of manufacturing when in mass production • Different components manufactured differently, so the prices vary • Different materials used and so a range of prices are noticeable Function • An everyday use lamp for a child/teen • A plastic ring to make it more realistic • A light bulb to give the glare in a room • Orange color which enhances the glare of light emitted by the bulb • A switch to flick it on and off at mood. Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • An open mouth for the heat to escape or else the plastic would start to burn and could cause a fire • An insulating wire which is safe for human contact • Plastic which does not overheat that often and quickly Size • Size suitable for a room table • About 30 cm tall and 45 cm wide • Simple size for a child/teen to use • Does not overtake place Material • Acrylic used for mass production of lamp • Glass used for bulb enhance the effect of light • A rubber wire to make it an insulator, prevent shock accidents Aesthetics • 2 different light sources to make it eye-catching • Has an irregular shape • Inspiration from squiggly lines • The black base complements the flair lighting • LED lights bring more information • The colors blue and pink contrast each other perfectly. • 2D and 3D shapes vary the looks Client • For people who are interested in astronomy and nebulas etc. • Blue and pink color fans • Teens over the age 10+ • Teens who are capable and intellectual to understand its function Cost • About 250 DHS • Many different process and manufacturing ways raise the bar • Different sorts of materials used • More electronics are involved with this • LED lights can cost a fortune Function • LED lights give it a more astronomical look • LED lights enhance the glaze effect, so do the colors • The switch is there to make is simple and easy for the customer to understand • Shape expanded in the area to spread light further • The LED lights are there to create and enhance the effect of normal lights • The base is to hold the LED lights and the switch connected • The base allows a group of wire to pass through. • The switch is there to turn the lamp on and off at mood Environment • The LED lights release heat • The plastic used for the base is made from oil, which is a finite source • Used battery to make it more environmental friendly. • Glass made from extreme pressure and heat, which could have possibly released deadly toxins into the atmosphere Safety • If left in a place of immense heat, batteries can explode • The glass can break and can injure people • The switch must be made from an insulator to prevent shocks the fact that Size • Has a thick base with a very tall LED light shaped as an irregular shape • Length about 45 cm • With is about 15 cm • The short width and tall length provides a push to spread the light in a dark room Material/Manufacturin g • Glass is there to cover the LED light to enhance the effect of light dispersion • Plastic base so that it insulates the electricity passing through • Switch also a plastic insulator • Different sort of procedure used • Laser cutter to cut out the base • Glass welding to create the shape Anthropometric/Ergon omic • The average size of an index finger can then provide the dimension for the switch Anthropometric/Ergonom ic • The average size of an index finger can then provide the dimension for the switch Aesthetics • A circular shape resembles a star • The black covering adds a bit of spice and excitement to the lamp, seems like its armored • A replica of the ‘death star’ from the movie star wars • The colors black and white complement each other perfectly • The holes on the black belt create a more catchy design appearance Client • For Star Wars fans • Teens above 10+ • People who are interested in the depths of space Cost • About 300 DHS • Different sort of manufacturing methods cost more • More materials cost more • Labor is not cheap nowadays Function • The LED is covered with a spherical shape which disperses the lights further • The black belt around out create a fancy lighting show. • The button on the bottom Is to turn it on and off at will • The black belt provides itself as a stand so that the lamp does not roll everywhere Material/Manufacturing • Glass used for the sphere to enhance the lighting for that • The black belt created through acrylic through injection molding • Holes created using laser cutting machine • Mostly used glass, acrylic or some sort of rubber plastic for the switch to make a perfect insulator Manufacturing • The ring was created through laser cutter • The cover is created through injection molding Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • The bulb is covered to prevent heat from escaping • Its spherical which prevents a injuries to occur • An insulating wire which is safe for human contact • Plastic which does not overheat that often and quickly Size • Size suitable for a room table • About 30 cm tall and 45 cm wide • Simple size for a child/teen to use • Does not overtake place Anthropometric/Ergono mic • The average size of an index finger can then provide the dimension for the switch
  • 7.
    Aesthetics • A ringto present meteorite fields. • A light blue LED to show the light in space from the stars • The irregular shaped base to represent the flying saucer of a UFO • Black and Blue compliment each other perfectly • Variation in the type of shapes available Client • For people who are interested in space and time • Intrigued about UFOs • Interest in Sci-fi • Aged 10+ Cost • 200 DHS • The LED light costs a lot due to its color • The base manufacturing is expensive • Money to be payed for assembly Function • The color of the light is there to enhance the level of brightness • The base is made curved to make it stable • Its there to give a more astronomical look • The switch allows you to turn it on and off at will. • The hole in the middle allows a hand to go through and carry the lamp where ever you want. • Makes it more portable Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • An open mouth for the heat to escape or else the plastic would start to melt • The base consists of sharp vertices which can be dangerous to underage kids Size • Must be 20 cm X 25 cm • The diameter of the circle should be 10 cm Material • Acrylic will be mostly used due its variety • LED light will be covered by either some heat insulating plastic or a glass that does not absorb heat • A good insulator for the switch Aesthetics • Blue light used to portray the color of the galaxy • A flat base shows how the universe looks from earth • Many mini lights portray the stars blinking in the sky • The brown color of the base compliments the black and blue Client • Who are interested about the expansion of the galaxy • Also those who follow the horoscope • Aged 10+ • People who understand how to work hand sensors Cost • About 250 DHS • Many different process and manufacturing ways raise the bar • Different sorts of materials used • More electronics are involved with this • LED lights can cost a fortune • Has a hand sensor Function • LED lights are there to enhance the brightness • The base is designed that way to make is stable and stand up still • The lights extruded from the base are done to bring a more realistic effect to the lamp • The lights are designed with a movement detector, as the hand waves pass the lights turn on igniting the room • The extrusions are aiming everywhere in a 180 angle to disperse the light even further Environment • The LED lights release heat • The plastic used for the base is made from oil, which is a finite source • Used battery to make it more environmental friendly. • Glass made from extreme pressure and heat, which could have possibly released deadly toxins into the atmosphere • The sensor could need more materials which could release toxins when being manufactured Safety • The extrusions could injure a person • The base could slip and fall on the ground and hurt somebody somehow • The lights could be damaged due to the excessive extrusion Size • Has a thick base with a very tall LED light shaped as an irregular shape • Length about 60 cm • With is about 15 cm • The short width and tall length provides a push to spread the light in a dark room • The light extrusions provide a better sensor position for it work Material/Manufacturing • Glass is there to cover the LED light to enhance the effect of light dispersion • Plastic base so that it insulates the electricity passing through • Switch also a plastic insulator • Different sort of procedure used • Laser cutter to cut out the base • Glass welding to create the shape Anthropometric/Ergonomic • The average size of an index finger can then provide the dimension for the switch • The average hand size is surveyed and found out, and then the ring is cut through that size because the hand will be going through it, to make is portable Anthropometric/Ergonomic • The average size of an index finger can then provide the dimension for the switch • The average surface area of a human hand is measure and the sensor is then detected on that measurements basis Aesthetics • A cuboidal shape resembles a part of a spaceship • The white color of the lamp provides it with a calm and composed look • The engraves flowers provides and deep insight and a meaning to the manufacturers thought process Client • For those who enjoy Sci-Fi • Teens above 10+ • People who are interested in the depths of space Cost • About 300 DHS • Different sort of manufacturing methods cost more • More materials cost more • Labor is not cheap nowadays Function • The LED is places inside the cuboid which allows the to disperse a white color • The flower engravement provide the magnification of a flower shadow • The button on the bottom Is to turn it on and off at will • The square base makes it stable showing perhaps how it will not fall Material/Manufacturing • Glass used for the sphere to enhance the lighting for that • The black belt created through acrylic through injection molding • Holes created using laser cutting machine • Mostly used glass, acrylic or some sort of rubber plastic for the switch to make a perfect insulator Manufacturing • The ring was created through laser cutter • The cover is created through injection molding • The Hole was creates through laser cutting Environment • Has an energy saving bulb, releases less waste comparatively to others • The spherical covering around the bulb absorbs he limited heat released from the bulb • The plastic its made from has gone through various different processes which release toxins in the atmosphere. • Plastic is made from oil, which is a fossil fuel and is an finite source of energy. • However, the plastics can be recycled but will need a high melting point which will release further toxins Safety • The bulb is covered to prevent heat from escaping • Its spherical which prevents a injuries to occur • An insulating wire which is safe for human contact • Plastic which does not overheat that often and quickly Size • Size suitable for a room table • About 30 cm tall and 45 cm wide • Simple size for a child/teen to use • Does not overtake place Anthropometric/Ergon omic • The average size of an index finger can then provide the dimension for the switch
  • 8.
    A working IKEA® lamp, basicallyused for studying in the nights or for when there is no light available in the room We firstly detach the base made from plastic which holds the is a step down mini transformer, it reduces the volts coming in from the mains which could damage burn the LED light We then detach the glass covering the LED light which prevents it from over heating the plastic and causing harm to the consumer. We use a 4 faced screw driver to remove the glass leaving the LED light exposed and detached from its position As you can see the LED light slot has been completely removed from it origin, plastic covering to prevent heat waste. We then detach the power source from the power switch, it requires just physical force and it comes out. We also remove the top retractable arm which is used to change the direction of the light Mini Components • 15 screws • 6 set of wires (copper) • Black plate-inspired bearing The power source is left as it is, the red wires, made from copper (conductor)are connected to the power switch and the blue wires are connected to the mains fuse, these wire complete the flow of current allowing the lamp to work • LED light (yellow) • Glass piece (circular • 2 bolts • 2 mini bearings Disassembly of a home lamp 1 2 3 4 5 Conclusions from Disassembly analysis • Make sure that your product can be disassembled easily • Try not to make it too complicated • Avoid over fitting components • Sensibly choose material depending on assembly and disassembly • Limit the screws, nuts, and bolts you are using during the manufacturing • Material should prevent over heating • My lamp would need to look better in its aesthetics, than this, as it is the most important aspect.
  • 9.
    Screws and bolts Advantages •Easy to attain from anywhere • Simple to fix, attach or assemble • Very cheap in the market, can be bought in large numbers • Provide tight joints • Prevents parts from falling apart Disadvantages • During the assembly, the screw or bolt should not fracture the material • From materials like acrylics, the nuts will become loose • Makes it looks messy • Doesn’t go well with weaker woods such as ply wood. Glass Advantages • Gives it a more production look • Produces better quality light then acrylic • Comes in many types Disadvantages • Over a time period, scratches start to appear • If it falls it will definitely break and shatter into pieces • Comparatively expensive to acrylic Plywood Advantages • Layers are glued together in right angles, which give it strength • Plywood is cheaper than other wood, a cheap wood which provides more strength than some expensive wood Disadvantages • The layering affect makes it porous and susceptible to water • Nuts and bolts can fracture the wood, so must be careful when manufacturing it Acrylic Advantages • Light weight, so its easier to manufacture and move around. • Style, it brings more style to a product than bland wood • Strength, difficult to bend or crack Disadvantages • The acrylics is easily scratch able • It does not produce the light quality as glass • Difficult to assemble MDF Advantages • A very inexpensive woods • It can be painted or stained to look just like normal woods, nice substitute of wood without paying the full price Disadvantages • MDF is weak compared to other woods • Due to it lack of density, more nails will be required to install it for the different places in the lamp • Nails can actually fracture the wood, damaging your whole product. LED lights Advantages • Energy efficient • No warm up period, doesn’t heat up which could melt the plastic • Environmental friendly, releases almost no waste energy • Excellent color rendering Disadvantages • LED are currently more expensive to use in mass production compared to other lighting sources • LED performance largely depends on correctly engineering the fixture to manage the heat generated by the LED • Must be supplied with correct voltage • LEDs shift color due to age and Spray Paint Advantages • Speed and accessibility • Even coating • Variety • High resistant to UV degradation • Wide range of effects Disadvantages • More skill required for even coat • More expensive than powder or liquid paint • Not as tough as powder • Solvent emission not good for environment Basic Components Analysis
  • 10.
    Manufacturing Research Band Saw Advantages •Allows any lines and shapes to formed on the wood or acrylics being used • Can also cut through acrylics and other plastics/woods Disadvantages • Band saw can crack/fracture the material being used • Starts to create a lot of bird or rough edges on the acrylic/woods. 3D printing Advantages • It has the ability to customize products • Rapid production of parts and prototypes • Not much expense is required Disadvantages • It does have a serious limitation of size, it can only produce until a certain size • Limitation of raw material, mistakes a viable, so raw material might start become an issue • Has a high electrical cost Vacuum Forming Advantages • Low cost tooling • Short lead time • Complex shapes easy to because the mold is easy to manufacture Disadvantages • It has a slow manufacturing cycle, longer time is required to provide the producer with the finishing good • Relatively high piece part cost, sometimes its components which need to be replaced are at high costs. Laser Cutter Advantages • Capable of cutting many materials and thicknesses • Cutting narrow kerf widths, which promotes efficient part nesting, yielding better sheet utilization and material savings • Easily and accurately repeatable • Reduced time for set-up with the ability to react and adapt quickly to changing production needs that are market or quantity driven • Efficient processing, as multiple jobs or parts can be nested and cut in a single program. • No secondary clean up process required for most materials, and is usually ready for immediate shipment Disadvantages • Poorly adjusted laser can burn the acrylic and cause a fire • Rate of production can be determined by the density of the material • Higher power consumption • Electrical cost is very high • Usually just 2D cutting Belt Sander Advantages • Used for the perfect finishing for wood basically • Acrylic can also be used on this to cut of bird and rough edges • Gives it a smooth and fine finish Disadvantages • Must be careful to check out the proportion of sanding. • Sometimes unevenness is created on the product • If human skin rubs on it, friction burn is caused and is damaging. Tennon saw Advantages • Used to cut wood pieces of all types. • Brings an even shape between 2 cut wood pieces Disadvantages • Requires a lot of physical force • Can slip and cut your skin • Friction burns are very common Coping Saw Advantages • Used to cut acrylic/plastics easily • Can bend while cutting and changing direction is possible • The blade gives a free move to the cutting Disadvantages • Requires a lot of physical force • Blade usually breaks/cracks all the time, spare must be available • Repair costs a lot • Cut cause friction burn or slip and cut your finger/skin
  • 11.
    Joint Research Butt Joints Avery simple joint but it is also very weak. They tend to be used for making picture frames, corner pieces and nails are often used to strengthen the joint. Advantages • Easy to design • Fits together with glue, no technicality Disadvantages • Weak joints, the glues usually wears out, especially when its acrylic • During assembly, placement can go wrong Mitre Joints Mitre joints are often used to produce the corners of picture frames and boxes. The mitre needs to be cut at a 45 degree angle, this is often used with a mitre saw that can cut at many different angles. Advantages • Easy to design • Fits together with glue, no technicality Disadvantages • Angles can be damaged or compromised during manufacturing • During assembly, placement can go wrong Finger Joints This is the strongest joint on this page, the only joint that is stronger is the dovetail joint. The finger joint can be difficult to make but looks very good. It has a lot of surface area to glue together Advantages • Larger surface to glue together • The technique makes it more durable Disadvantages • Very technical, all dimension must be taken into consideration • Sanding in order to improve aesthetically can damage the fitting Housing Joints This is just a simple slot cut into one piece of wood to increase the glue area. This is often done with a router and works very well in MDF. Advantages • Very simple to generate • Glue area increases, improving durability Disadvantages • Assembly can be tough • Fitting is very important to be spot-on
  • 12.
    Research What Ifound out? How will I use this information in the manufacturing of the product? Mood Board • In my mood board there was a large number of spheres • Large quantities of images taken by telescopes in space • Seem very futuristic and artistic in a way • Try to impose a sphere in my final design, especially when its voted the top shape in my questionnaires • Bring a futuristic, Sci-Fi and space effect to it Questionnaire • Sphere was chosen as the favourite 3D shape • People chose battery over mains. • LED lights received the majority of the 50 people vote • People want a link with the movie Star Wars®. If possible, but not necessary as it should more importantly be linked to Sci-Fi and space • People are only willing to pay 60 pounds for a sci-fi lamp • I need to somehow impose the sphere shape in to increase the sale price or quantity • The argument on mains or batteries is comprisable. • The colours should basically be the ones voted the highest • Make the product as cheap as possible, with the highest quality to achieve maximum profit Product analysis • Every product definitely has its pros or cons • Always try to reduce the cons for better production • The lighting must used safely. (heat as waste) • Colour combination improves the most important aspect, Aesthetics • Figure out the pros and cons, and try to unbalance them out, in a way that the pros are greater than the cons • Figure out how much voltage or energy the light in your lamp will require, would you need a resistor if its connected to a mains? Basic components analysis • Limiting the nuts and bolts decreases the probability of a fracture or a damage. • Plywood is stronger than MDF, however, plywood is porous and susceptible to water. • Spray paint is the best option when it comes to painting wood • Try to reduce the bolts used in both acrylic and wooden part of the lamp • I would use plywood because the strength basically matters, because no one is going to take it close to the water. • LED lights produce the least waster energy after the light saver and the fluorescent light, but it provide better quality Manufacturing Analysis • To make a sphere, I would have to use either the 3D printer or the vacuum former • For the base using the tenon saw would be best • To shape and cut through acrylic, a coping saw is ideal, though it is easily damageable. • It should be as efficient as possible, use up maximum amount of the resource, not wasting any • I will have to look into more detail in which is the ideal machine to use for creating a sphere, would it be the vacuum former or the 3D printer? • The base is basically going to be either a cuboid or cube inspired shape or it could just be any wooden base. • It should be hollow from the inside because that’s where the mains or battery socket wires will have to go • Any acrylic part of the lamp must be crafted either using a laser cutter or a coping saw if u want it hand craft rather then CAD/CAM-ed. Disassembly • Limiting the mini components eases the manufacturing process • Makes it easier for mass production, the manual is not that condensed with content. • Choosing material wisely, depending on manufacturing process and mini components • Should basically be easy in assembly and disassembly • Material should prevent over heating • Make sure that your product can be disassembled easily • Try not to make it too complicated • Avoid over fitting components • Sensibly choose material depending on assembly and disassembly • Limit the screws, nuts, and bolts you are using during the manufacturing • Think about the consumer or the assembler, how should you make it, so that’s easy to assemble and disassemble • How would I make it that it would make life easier for a illiterate consumer and an unskilled worker • Plastic would be most suitable to prevent my product from over heating.
  • 13.
    Specification/quality control Function • Itshould provide sufficient amount of light for reading or studying • It should be portable anywhere around a room • The on and off button must be working flawlessly Aesthetics • My product should follow my Sci-Fi/Space theme • Lamp should not have any bird edges, or anything that makes it look messy • It must have majority of the colors which were chosen in the questionnaire • No rough edges of the wooden base or any dripping paint be visible to the costumer Safety • It should not have anything pointy sticking out of it, because my product is basically for teenagers, who make harsh decision very quickly • It should be in a state where it falls of anywhere it is kept, because if it consist of glass, then it will shatter everywhere Size • As the majority of my clients stated that he/she wanted between 30cm^2 – 50cm^2 • Must consist the shapes which were chosen at a majority between the 50 people such as a sphere or a cuboid Customer • Its mainly for people between the ages of 10-20 (adolescents) • For people who are into the Sci- Fi/Space theme • He should also have interest in mechanics, technology and modern looks Material • As I went into further detail in my research on materials, I found out that the best wood to use was either plywood or MDF, because they both can be used for good finishing and drilling in bolts, nuts and screws. • Acrylic would be a better option than other sort of plastics or even metals, because they require more effort and machinery • Bolts and nuts should be reduced as possible as they can fracture the material or component • LED is the best option as it was the major choice in my questionnaire and it has the most advantages Ergonomics • The average size of a human is between 2.75-2.49 inches, that’s how big the on and off button should be Cost • After my client interview, he/she was willing to pay 60 pounds for my product, which covers my cost and gives me a 20% profit Environment • My LED lighting should release the least possible waste energy (heat) • I should be as efficient as I can be when consuming my resources at hand. • I found out that the product must be as efficient as possible using up less energy, not wasting any resources and not pollute the atmosphere through emitting toxic gases Manufacturing • Try my best to impose as many techniques as possible such as vacuum forming, 3D printing, CAD/CAM, Laser Cutting, Sanding machine, Band Saw • Must use more finishing techniques to clear things such as bird and rough edges • It should be simple and efficient to assemble and disassemble the lamp
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  • 15.
    Inspiration from mood board Usedplywood to bring the look of the satellite panels, possible engraving can be done on the edges to help it aesthetically Sphere was made by using translucent acrylic, it was an idea to go for colored acrylic, but I had to put a LED light inside the sphere so that it would disperse the yellow light. Used dowel joint to form the panel-inspired wood pieces into the sphere, they can also be used to carry the whole lamp, making it portable and also provide it the stability of staying still on any position you put it in. I created the sphere in 2 semi circles and joined them together, but they both had to be hollow, so I used the vacuum former to make it work Inspiration basically came from a moving satellite, but because I also had the Sci-Fi theme, I put a sphere in the middle to make it look like a moving scanning probe. 1 Inspiration from mood board Formed 2 circular based pyramids and joined them together, to make them look like a an hour glass, top part will hold a red LED light (due to the questionnaire) and the bottom part with blue. They are joined together as a bottle cap is joined to a bottle. It helps in its disassembly if you require to change your LED The hour glass inspired lamp will then be joined together with a cuboid which is made using plywood, and the pieces joined together using butt joints. The hour glass lamp will sit on the cuboid and will be connected using a dowel joint, and the wires will then pass through for the LED light in to the battery slot to make it functional The on and off button which is connected to the battery slot inside the cuboid, obviously there are screws above the switch to open the flab and change the battery if needed. The cuboid which is the base of the lamp, providing it the stability it needs to stand still, is made using 6 pieces of plywood, all connected using wood glue. However the right end of the cuboid was joined using screws or hinges, to be able to open it and make changes in the battery. Inspiration basically came a photo taken by the Hubble telescope which reimages a picture of an hour glass 2 I used the 3D Printing machine to make 2 semi-circles and then joined them together using dowel joints, it was made using acrylic. The cuboid was made using MDF, 4 pieces were cut out in certain dimensions (through trial and error methods) and then were butt jointed together using nuts and screws, so it would help in disassembly. The wires will be going down through this into the base were the battery socket is placed, its colored black due to the majority of votes from my target audience This was actually made using 2D design, I made the dimension and then using CAD/CAM designed it on a software, and then used the laser cutter to cut it out, could be colored acrylic or thin wood, this is basically for the battery socket and has the wires go into it Inspiration from mood board Inspiration basically came from a hovering space ship shaped like a tower, so the sphere on the top represents theme, and the bottom bases represent its mechanism . 3 I used the 3D Printing machine to make 2 semi-circles and then I joined using an either, mortise or a tennon joint, which suits it the best The ring around had to be attached using dowel joints, we had to poles made from any soft wood sticking out which we then connected with the ring around the globe, it just makes it easier for assembly and disassembly, because not 1 screw or bolt is required For this I will be using the mains as the power source, because it is difficult to fit in a battery socket, and will have a on and off button on the bottom Inspiration from mood board Inspiration basically came a photo taken from outer space by a telescope, it shows a gas ring around the spherical planet, this is what I tried to replicate 4 Size Length: 25cm Width: 10cm Size Length: 10cm Width: 20cm Size Length: 25cm Width: 10cm Size Length: 15cm Width: 20cm
  • 16.
    3 spheres madefrom acrylic, so technically I had to manufacture 6 semi-circle which were hollow from within, and then joined them together using tennon joints Method 1 I either take a long piece of MDF which has a width of about 25-30 cm, spray paint it blue, and then use a band saw to cut out the curves which are required. Method 2 I take a long MDF piece, around 25-30 cm and place it in the 3D printed and use CAD/CAM to get my product manufactured Inspiration from mood board Inspiration basically came from a microwave background radiation going through a planet with a gas ring and electro magnetic ring around it I will be using the mains as the energy source (due to the questionnaire), so it will not require the wooden base to be opened in any way. However, the spheres may have to be opened now and then to change the color of LED light (originally YELLOW) or to actually change the light because its gone bad Size Length: 10cm Width: 30cm 5 I will use a coping saw to cut and shape out the acrylic tops and bottoms. I could either do that, or make separate pieces through CAD/CAM and join them together.. The battery socket is in the top red portion, with a black switch, brings a hint of dark matter from the space. The middle cylinder I might have to buy ready made, due to the lack of resources and equipment in you school., Unless, I decide to manufacture the cylinder in a 3D printer, the issue would be how to make it hollow from the middle, which I might have to do by hand, which could damage the product. It will have a fluorescent light inside it, which will be a yellow color. The top and bottom open up like bottle cap making it easier to replace the light The color scheme Red, Yellow and a hint of black was inspired through an image from my moldboard and the questionnaire where yellow and red were rated as one of the highest Size Length: 25cm Width: 5-10cm Inspiration from mood board Inspiration basically came from a Higher ranked droid in Star Wars ® which gave me the idea. The height was basically inspired by it and it have a battery as its source made it look as portable as a droid. 6 The sphere was manufactured using vacuum former, 2 hollow semi circles were made and joined together either using tennon joints or basic slots. 2 cuboids of MDF was taken and manufactured in a way to provide support for the globe, with the blue LED light. The front face edges were manufactured using belt sander, and were sanded until a 45 degree angle. They are then slotted in to the sides of the globes. These will consist of my battery power, and the on and off switch. I will use adhesive paint sprayers to coat the woods red and black due to my audience voting it at the top. Inspiration from mood board Inspiration came from a space ship shaped in a glass globe with 2 pointy sticks pointing out of it, I used the design to support by globe. Size Length: 5-10cm Width: 20cm 7 I will be manufacturing 4 mini spheres using 3D cutter made from plastic and the larger sphere on top will be manufactured in to 2 hollow semi circles and connected together using a joint. They will all consist of Blue LED lights The base is made from MDF with a length of 10 cm and diameter of 10 cm, this was produced using laser cutter, through CAD/CAM. The long cuboid in the middle is the place where the battery is stored and the wires travel through, made from Plywood. The 4 other 90 degree arms are made from acrylic pieces joined together, and joined into the large Cuboid using joints, and the mini spheres are attached to their tops, they will also be BLUE LED LIGHTS. Inspiration from mood board Inspiration came from a space ship with held more that one heads, in different places, the cuboid and sphere were the highest vote attained in my questionnaires, so they had to be imposed Size Length: 25cm Width: 5-10cm 8
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  • 18.
    Sketch Sketch 1Sketch 2 Sketch 3 Sketch 4 Sketch 5 Sketch 6 Sketch 7 Sketch 8 Brief Description Grey and Yellow one of the colors picked by majority of the audience Consists of a sphere which was voted top in my questionnaire. A satellite-space ship inspired lamp is for creative people, the colors grey and black bring it towards more Sci-fi and space theme relation how nothing has a color in space, inspired from the movie Star Wars(r0 Shaped as a sand clock Slotted on to a cuboid wooden base Consists of blue and red LED lights Very classy and old type look, makes the elderly feel nostalgic. The cuboid is what brings the simplicity in it altogether, having a complex designed and manufactured shape over a simplebasic shape makes it unique Base is red colored with the middle cuboid blackand the top globe translucent but containing a Yellow LED light which provide Yellow light Contains a sphere in top which represents space and planets A towering building representing the building in the republican from the movie star Wars® Contains a sphere in the middle as the disperserof light. The bulb will produce yellow light as stated in the initialideas, due to majority of the vote to yellow Contains a Blue ring across it which contains mini LED lights (Blue) Very basic object and shapes used to make a complex idea, whichattracts the consumer The base of the lamp was colored blue due to majority of votes considering blue to be a highly wanted color The curvy base is inspired by a strand of DNA found in the vast skies of space The spheres represent Civilized planets with yellow/greenlightings Contains a cylinder in the middle with 2 trapezium based pyramids on top. The cylinder has a yellow color due to majority of votes and the trapeziums are red, I was told that the combination of yellow and red is very appealing Color schemerelating to a droid from the movie Star Wars® A sphere was induced into the product which ticks of having a sphere in the product from the specification. Contains the Blue LED light due to the majority of people coting for the Blue color in their questionnaire. Having slim wing on the side of it brings the theme of aliens space ship. Contains a mixture a color which is attractive to the consumer, brown to give it a wooden base look, blue painted tower made from plywood, with 4 arms sticking out holding4 spheres with yellow lights as requested in the questionnaire The largest sphere in the middlewhich is also yellow color whichincreases the radius of the light dispersion. Aesthetics 6/10 5/10 7/10 7/10 7/10 6/10 5/10 9/10 It should be affordable for parents and not to expensive to prevent maximization of profit Did not have a large cost of production Should be cheap and affordable to teens and parents. Had a high production cost which causes an inflation the price of the lamp compared to the other lamps in the market Not too expensive but not very cheap Suppliers would request 20% more of the cost Little bit expensive Due to extensive care and methods of production Difficult to manufacture and requires a lot of fixed cost, which is included in the price Has a reasonable price compared to its cost The producers are only looking to have 20% profit, which would be a8 pounds more than the production cost, which would be around 48 pounds Cheap and affordable. Production cost is not very high, and the suppliers rare willing to only add 10% profit for them self, taking the products to price of 40 pounds. Cheap and affordable Has a very small productioncost, and the producers have this being sold as a minor product, wo they do not require high percentage profit but only about %, which would be about 25 pounds Cheap and affordable The production cost is very low and looking at the versatility of the lamp only 10% profit added on is a fairly reasonably price, making the it 55 pounds Cost 8/10 2/10 2/10 3/10 8/10 8/10 8/10 9/10 Ages mainly between 10-20 Consumer interested in more space dominated theme with a hint of Sci-Fi More of a space ship and satellite inspired lamps A satellite and alien space ship combinationis for all Sci-fi and space lovers Teens between 10-20 Old Sci-Fi themed designs such as sand clock Red and blue color scheme lovers More older type Sci-fi for older people into sci-fi More scientific and classy type look Between ages 5-15 Very simplenot attractive to older audience Audiencewho prefer to have longevity than width of the lamp Inspired from the towers in the republicanin Star Wars ® The globe also gives off injection of static electricity for science lovers. Kids between ages 6-10 mostly from rich families Very basic shapes, not appealing to older year groups Client interested in more space than sci-fi More of space centered theme, where inspiration was takenfrom a Hubble telescopeimage and reformed by the hands through production Between ages 10-25 Has a more complicated hint to it making it more appealing to older aged groups. Audienceinterested in space and Sci-fi inspired lamps For audience who like to have a more complicated and modern design to their sci-fi and space themed lamp. Kids between 9-17 Not to complicated, simple button, simpledisassembly etc. The colors scheme is more droids Sci-Fi space type which would suit teenagers of the 21st century Audiencewho are into the longevity of a lamp which allows the light being disperse to cover up larger radius. Kids between 5-10 mostly boys Very simple, teenagers wont relate to it, as they are to old for space ships and ben ten inspiredproducts. Teenagers would find it harder to relate to the theme of Sci-Fi, as they look for more Sci-Fi or space inspired movies. Audiencewith a very basic and simple state of mind, who dislikecomplications and promote simplicity. Between ages 10-20 Perfectly fits my specification due to the versatility in the design of the product. Not to complicatedand not to simple right in the middleattracting a large group of people in that age group. Good use of color scheme from questionnaire. Client 7/10 5/10 3/10 5/10 8/10 7/10 3/10 9/10 Doesn’t require much energy to manufacture Its repairs do not require any heavy machinery A lot of trial and error methods were used wasting resources. The light bulb released to much heat waste . Recyclable materialsused. Fewer energy used to produce Not much saw dust was produced which is harmful to the environment No melting the plastic or molding metal. A lot of trial and error methods were used wasting resources. Recyclable materialsused. But uses electricity so has carbon impact Production of it releases a lot of fume in to the atmosphere Sawdust very dangerous to human health when manufacturing wood A lot of trial and error methods were used wasting resources. Not environmentally friendly. Requires intensive capital labor (machinery) Whichproduces fumes such as CO2, CO etc. whichall contribute to global warming The light bulb is an inefficient bulb releasing50% heat in to the atmosphere A lot of trial and error methods were used wasting resources. The base wood goes through a whole methods of cutting releasingexcessive saw dust damaging to the human environment. How ever not much energy is need to manufacture the mini 3 spheres. The light bulbs are energy savers which makeit more efficient reducing %age of heat being produced from the lamp A lot of plastic was used generating a lot of fumes in to the atmosphere contributing to global warming The LED light is of bad quality (cheap) still has a high percentage of its energy yield turning into waste heat energy The plastic heated to make the mold of a cylinderwas done through trail and error wasting pieces of plastic. Has no recyclable materials, and the production of it creates and damages the environment The manufacturing of it contains the use of heavy intensive labor whichrequires a lot electricalenergy releasing a lot of waste energy to the atmosphere contributing to global warming. A lot unhealthy toxic fumes are generated Made from thermos plastic acrylic which can be heated an reuse again in other manufacturing processesfor different products in different markets. The wood being used is MDF which is recycled from the saw dust being smashed together. Increased the productivity yield 10 99%, to make use of every single resource used. Environment 5/10 7/10 4/10 1/10 8/10 5/10 4/10 10/10 A few sharp bird edges and the globe could most probably over heat due to lack of protection Can easily fall to the ground due to lack of stability and shatter to pieces. Or could have splinters from the wood everywhere No sharp edges or small parts. Edges are finely sanded Wires willbe exposed so must be careful Easily exposable to water, which cancause short circuit. No sharp edges. Not to heavy All vertices of cuboid while be sanded into a curve Made acrylic does not hold heavy components. The base had sharp edges which could have been dangerous to underage siblings in a family. No sharp edges or small parts. Releasesa sufficient amount of heat energy as waste (50%) Very unstable and can collapse to ground shattering into piece The ring is a very sharp object and can cause cuts and injuries to consumer. Has a few edges but can be easilyfiled or sanded off using a filer or sand paper with different surfaces for different finishes The lightingis an energy saving bulb which makes it more efficient reducing chances of skin burn, The 3 bulbs are heavily exposed which could cause over heating No smallparts Contains many vertices, which can be dangerous for younger category of the clients. Very tall and can fall easily and shatter into pieces which would make it difficult for people to actually Has a few edges on the wing based wooden pieces, very sharp and can harm consumer The globe is ratio wise bigger than the wings, which increasesthe probability of it dropping to the ground and hurting the consumer. The LDR light can over heat catching fire Contains many sharp edges but can be filed and sanded through sand paper, filer or even the belt sander to provide good finish and prevent any injuries to the consumer. The spheres are perfectly attached to their bases through certain joints The arms provide it further stability preventing it from the ground in a split second. Safety 4/10 8/10 8/10 2/10 8/10 6/10 5/10 9/10 10cm x 20 cm Suitable size for a satellite inspiredlamp 25 cm x 10 cm Depending on its components, the size is perfect 25cm X 5cm Length is too long for teenagers to be careful with 15cm x 25 cm Suitable and balanced height for a sphere-globe inspired lamp 10 cm X 30 cm Looking at the shape of it, the size is at its most suitable 25 cm X 10 cm Due to its towering body, the width length is comparatively proportionalto the length it has, giving it stability 10 cm X 25 cm Ratio wise the size is not suitable, and will create difficultiesin manufacturing 25 cm X 15 cm Perfect size depending on the retractable arms on around the cuboid provide further stability. Size 7/10 8/10 5/10 7/10 9/10 9/10 4/10 9/10 Must provide efficient light for the buyer Should be able to stand easilydue to the wings provided. Easily portable The Sphere increases the dispersion radius of light The wings also hold the battery socket and the witch to turn the lamp on or off. Provides a mixture of lights, not suitable for teens studying in the nights Provides sufficient light for other uses The base provides stability for the sand clock inspired acrylic lamp The right flap of the base, is attached through hinges which is detachable to change the battery socket. The slot underneath the sand glass inspiredlamp is made to be sat above. Towering body to disperse the light to further areas The bottom wooden base gives it the stability and position it requires It has flappingsides to place the battery socket in and to connect the switch to. The right flap of the long cuboid is joined through hinges and detachable anytime to change the battery source Easily portable due its balanced size and shape The ring around it provides it with the minimum stability required to stand still in its designated position allocated to it by the consumer. 2 semi circles are made to make it easier for disassemblyand changing the light source The ring being attached through 2 rods to the sphere shows a change in the LED lights when a certain mod is applied to it. 3 spheres provide more sufficient lights for a dark room. The curvy shaped base is there to support the 3 sphere to disperse at their best possible radius. The right end of the base contains hinges and opens up to change battery The small clips on the spheres are there to make it easierto open them and change the bulb, the switch turns on and off It having small width provides easy accessibility and easily portable. The top trapezium can be opened as inspired by the bottle cap and the bottle itself The black switch on the top trapezium is there to turn the lamp on or off. The cylinder holds the Yellow LED light The top also has the mains connected it, which continuesinto the cylinder The wings are there to provide minimalsupport and stability to the sphere so that it doesn’t always completely fall down and damage itself. The button on the switch is connected to wire going through the globe and coming from behind it connecting to the mains as it is the power source of the lamp. The sphere was induced into the product due to its increasing in portability or accessibility of the product. The larger numberof spheres attached into one condensed area increases the radius of light dispersion, creating efficient light for the 10-20 year old to study. The base on the bottom hold the battery socket or mains which ever seems suitable at the time of production. The towering cuboid in the middle is there for the retractable arms. The arms are movable concentratinglight on certain objects, places of people Function 8/10 3/10 8/10 9/10 8/10 8/10 6/10 9/10 Sphere is made from 2 separate pieces of acrylics Joined together using joints or glue The wings are made from plywood manufactured using tennon saw or band saw Dowelljoints had to manufactured using had craft wood to make it easier for joining Requires a lot of material Difficult to join an acrylic product to a wooden base Base made from Plywood The top sand glass is made from 2 different colored acrylic using coping saw to manufacture and CAD/CAM to manufacture the base The right flap attached through hinges and openable for disassemblyand assembly Basic wood and Plastic was used Globe/Sphere was manufactured using3D printer to create 2 hollow semi circles and then joined together using doweljoints The base was manufactured usinga tennon saw to cut out the wood and the same for the towering cuboid which is joined through 6 pieces using wood glue. The base was very thin and made from MDF so smacking in nails, and bolts would do not favor, so attention had to given. Only Acrylic (plastic)was used in the manufacturing of this product 2 Semi circles were manufactured using vacuum former and joined togetherusing butt, tennon or mortise joints to make it easier for assemblyand disassembly. Ring was made using CAD/CAM through Laser cutter then heated and molded into ta oval shape around the sphere Joiningthe ring with the sphere had to be done using 2 rods connecting it from exactly opposite sides Wood (MDF) and plastic (Acrylic) were used The spheres were made suing 3D printer and joined together using joints, and were given clip type buttons which when adjusted would detach the spheres and expose the LED light, ready to be changed The base was made mostly using CAD/CAM and laser cutter but some parts were made using tennon saw and glues together with the rest of the pieces to make th inspired shape.. The materials acrylics and Plywood were mainlyused The cylinder was made using a2D rectangularpiece of acrylic heated and molded round into a cylinder with open faces We then manufactured the wooden trapezium using either 3D printer, CAD/CAM laser cutter or just basic tennon saw and belt saw. The bottle turning pathway was made using computer aided design and completed of using D printer The sphere made using vacuum former and 3D printer, 1 hollow semi circles made using 3D printer and the other one was made through the vacuum former to create separate joints and join them up together to complete the 3D shape. Basically made from Acrylics and plywood, as they are the easiest to manufacture and produce and cheap in comparability to others. Had to create a certain position for the bulb to fit in the sphere, so a drilling machine was used to mark a position Mini sphere manufactured using 3D printer after designing on CAD/CAM and the large sphere on top was manufactured using the vacuum former which makes it efficient. The base was made form MDF and the cuboid tower was made through manufacturing of plywood cut through laser cutter after being designed on CAD/CAM and joined eitherusing glue or joints. So are the arms which contains hinges making it retractable and movable to any position required, to concentrate in any position Materials/Manu facturing 8/10 8/10 9/10 5/10 9/10 9/10 7/10 10/10
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  • 20.
    Sketch 5 Sketch8 My initial design basically came from one of he pictures/images in the mood board. This is what was the first thing that came to my mind when looking at the picture, and I will now further develop it using focusing on certain designing aspects of the design Inspiration from mood board This was the image where I got my inspiration, its what gave me the idea of actually making the product in such a way Rather than having 3 under tunnels on my product, and 3 light sources in 3 spheres, I decided to have one upper tunnel, where 2 spheres can be condensed together with LED lights The Spheres will be a foster white acrylic with 2 LED light sources, with the body of the lamp made from Plywood either through CAD/CAM and laser cutter or just manufacture it using a band saw and a tenon saw, gluing them together The spheres will be slotted in together into the base of the lamp, either using dowel joints or just another form of connection because through my research I had found out that dowel joints would be perfect for joining components.. There will be partition on top of the bottom circle to prevent it from movie, but will be retractable to open and change the LED light After the development of the design I had found out that I would be using up less resource, which per y specification is a good idea, I have to make it as eco friendly as possible, and rather then using 3 spheres with 3 LED light sources, I would just use 2 of them condensed in one are to reduce the waste heat energy being produced and emitted into the atmosphere Environment Wing function The wings on the side allow the lamp to be set or placed in 3 different position, this improves its adaptability Cost The cost of it automatically reduces due to the les consumption in energy and resources, falling from 48 to 35 pounds Inspiration from mood board Inspiration came from a space ship with held more that one heads, in different places, the cuboid and sphere were the highest vote attained in my questionnaires, so they had to be imposed My initial idea came from one of the pictures in my mood board. The first sort of inspiration I get from that picture Is what I used to design this lamp, with some obvious changes in its certain aspects such as aesthetics, shape, sizes etc. Through looking back at my color scheme in my questionnaire, it showed how yellow and black were one of the top rated colors alongside blue, so a color of scheme of at least 2-3 colors was also requested by my client, which is why I took this step in its developments. Also the color scheme blue and red was to old Color Scheme In my initial design I had 5 spheres (1 large sphere, 4 small spheres), but due to the fact in my research and client interview, it had to be as efficient and eco friendly as possible, so to reduce such heat waste energy, I decided to deduct the number of light sources by 2, but they still consist the LED lights (Yellow) as the were rated highly in my questionnaire Base size In my initial design, the base had a smaller length or thickness, but after some further research on stability of products, I found out the base must provide the main stability and stating the fact the top parts are heavy, the base must be able to go under such pressure. The color was changed due to the review of my client, he stated that he wanted only 2 different colors on the body, rather than 3, and through my questionnaire these colors made the perfect scheme Environment The two arms are there to provide sufficient stability and improve the dispersion of light, as quality of light was to be taken in certain thought from the interview with my clients. Arm Function Cost My initial design was ought to calculate up to 55 pounds, however, after taking out 2 light sources, , the price drops by 20% to 44 pounds
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    Model dimensions fordeveloped designs
  • 22.
    Sketch 5 Developmentmodeling I used 2D design to sketch the 2 faces of the product inspired from sketch 5. It was a better way to manufacture the lamp model in this way, because it would have been difficult to include the curves of cardboard etc. Minimum space was covered to prevent from wasting cardboard as we had a shortage of resource. Made it more efficient. One of the specifications in the environmental part of the product was for it to be as eco friendly as possible. I had to use the 2D design to make the pieces that would join the 2 faces back to back of each other, to do that I had to get similar measurements, and make sure that were accurate. Length x Width Quantity 2 cm x 5 cm 2 7.6 cm x 5 cm 1 5 cm x 3 cm 4 3 cm x 5 cm 4 13-15 cm x 5 cm 2 I had to work out the dimensions of these pieces in relation to the 2 front and back faces of the lamp, to prevent a clash in sizes. Some of them I was unable to calculate due to certain limitation, so when the 2 faces was laser cut I used a rule to measure certain lengths and widths and used a cutter and a cutting board to manually manufacture some of the pieces.. This is the 3D model sketch of the base of the product with out the spheres, which are identified to be bulbs containing yellow LED lights because that’s what people who voted in my questionnaire wanted I was unable to manufacture the models of sphere through plastic, because firstly we lacked resources and we lacked the equipment of turning cardboard into sphere, so to represent the sphere I laser cut through designing on 2D design and added slots to them of 3.5cm x 1 cm, and will then be slotted together and placed into the base which is made from cardboard as well representing a wood base. The front faces I had cut out using a laser cutter, but a few of the small pieces I had to cut using a cutter, which I did using the same sheet of card board to make it as efficient as possible, and then I glued it together in the smallest time possible, as I had used only one stick of hot glue gun, so prevent heat energy from being released Making the Model
  • 23.
    Sketch 8 Developmentmodeling Length x Width Quantity 2 cm x 8 cm 4 2 cm x 2 cm 2 4 cm x 2 cm 8 1.5 cm x 2 cm 8 1.5 cm x 1.5 cm 2 2 cm x 19 cm 1 Circle 6 cm x 6cm 2 TOTAL 27 I had to look at the developed design and think of which pieces and what quantity will I need them in. I also had to figure out the dimensions for the pieces, and they had to be in all relation to each other, so there is not even a single clash in sizes. All these dimensions were put into a CAD/CAM software and drawn through software These are the dimensions and quantities of the pieces needed to make the model/prototype. There were a total of 27 pieces consisting of pieces with different dimension, all these pieces were manufactured through cardboard, as we did not have enough plastic to make a more stable or better quality model Manufacturing the Pieces The pieces were manufactured through a CAD/CAM machine, commonly known as the laser cutter. You must input the density and mass of the material which is cardboard, and so it starts to cut the pieces through a laser heating certain areas of the card board. To save resources and make it as efficient as possible, as it was one of the environmental aspects requested by client, we brought all the pieces very close to each other, to waste as least as possible I first made the base, by curling up the long rectangular piece and stuck the 2 circles back and forth using the glue gun. I then made the long cuboid body, by joining four pieces together, and then did the same for the arms, which were then all connected using the hot glue gun. For the 2 mini spheres and 1 large spheres, I had to represent them through a candle and 2 small bottle caps, because I had lacked resources to actually make a model for a sphere, I decided to represent them through other objects, after all it is a model The Model Making Method Main large Bulb represented by Mini candle 2 mini bulb represented by 2 bottle caps
  • 24.
    Strengths and Weaknessesof the models Model Of Sketch 5 Strengths Weaknesses The sizes were a perfect fit, all the pieces came together due to the accuracy of the measurements I was unable to manufacture the curved cardboard piece to go inside the body It was manufactured through pieces being cut in the laser cutter, making it very easy. Manufacturing the sphere through cardboard, and we did not posses enough plastic either 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 property in 2D design (software), it resembled exactly like the drawing. The glue gun had good effect, however it had unwanted strings of hard glue everywhere, which brought a weak aesthetic aspect to its part Lack of colors made the model look aesthetically weak Model Of Sketch 8 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 Using the bottle cap and candle as models of sphere bulbs was not the best of ideas, as it brought the aesthetics part of it to its weaker side The base was really stable, because of the extreme flatness in the circles 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
  • 25.
  • 26.
    The base willbe manufactured by using MDF. I will be using a tennon saw to cut out the shape or using the band saw is also an option, as I had found out through my research that they would be the best in cutting wood into different shapes, woods such as MDF, Plywood. The bulbs will be made using clear acrylic and will be manufactured using either a 3D printer or a vacuum former, as I found out through my research they were the best machines to make the spheres. I will make 2 semi hollow spheres and join them either using an adhesive or a wood joint such as tennon, mortise or dowel classified to be the best at the job I will be using the laser cutter to make the front and back face of the body as a whole, and then cut out the other pieces separately, and join it together using a wood adhesive, As per the results on my questionnaire, I had found out people preferred to have a lamp with a battery as its energy source rather than the house mains, so the switch is connected to the batter which is connected to wires coming from the bulbs through the whole body of the product. Why is this the best model • Firstly, the base is a flat circle of MDF, which shows how strong and stable it is • 3 spheres containing LED lights are spread out in the best of positions to disperse the light as far as possible, as per the specification • The design is a merger or a rebirth of the 2 developed models I had made through 2 of my initial designs • This design embodies the theme of Sci-Fi and Space perfectly. How does this portray the theme? The base representing a flying saucer which is part of a Sci-Fi aspect or feature, with the space ship inspired body, space is resembled through it, and in the end with the 3 bulbs on the product, it just puts together the 2 similar theme as the cherry on top. Using the Questionnaire Green = Achieved Orange = Moderate achievement Red = Failed • The LED lights • Using MDF or Plywood • Sci-Fi and Space theme • Battery as an energy source • Have any of the 4 colors, Red, Black, Yellow or Green (3 colors must consist in the product, as per specification) • Most important aspect (Aesthetics) off the charts and visually pleasing • Have it linked to the Star Wars® movie (basic inspiration) • Contained Spheres Environment/Sustainability • LED light being used as light source is a very eco friendly idea, as it does not release any sort of waste energy dangerous to consumer such as heat • MDF can manufactured using human force, and does not require the laser cutter to be used and use up electricity, and its easily recyclable. • Along with MDF, Acrylic can be recycled easily, and can be disposed of easily due it not being glass and harmful to the nature or the consumer himself Inspiration for the final design (from mood board, sketches and development)
  • 27.
    Parts assembly X2 Orthographic Drawingand Components of Product
  • 28.
    Model of thefinal design The bulbs will be made using clear acrylic and will be manufactured using either a 3D printer or a vacuum former, as I found out through my research they were the best machines to make the spheres. I will make 2 semi hollow spheres and join them either using an adhesive or a wood joint such as tennon, mortise or dowel classified to be the best at the job I had used the table as its base so that I would not have had to waste anymore resources to make the base, as it could have just been easily substituted for the time being, making the process of my product production a whole lot more efficient, due to it being the request of my client. The body was made through using the foam material, and was sliced into shape through a band saw, I first got rough and raw measurements and then I drew the shape to size on a large rectangular piece of foam, and then I used the help of my teacher to cut out the shape of the body which replicated the acyclic body The spheres were made in parts, firstly I manufactured 6 2D circles through the laser cutter, with slots in them, to connect, and then I placed cut out skin tights over them to keep them in place, and give it a sphere looking aspect This is the 3D Auto-Desk inventor 2015 model, I used my past experience with this software to plan out every single part of the lamp and assemble them together and give it a color scheme. Autodesk inventor 3D model (CAD) Strengths Weaknesses • The band saw was able to craft a very accurate and perfect body from the foam • The sphere-representing objects don’t really weigh much on its aesthetics aspect • The slots in the circles did well to hold together. The perfect weights allowed equal momentum on each arm. • The arms of the body were made too big, and it base was smaller, so it would sometimes become unstable and collapse MODIFICATIONS TO FINAL PRODUCT (big changes) • I would have to keep in mind the scale ratio of the base and the body, so that it does not fall off all the time • I would stuff the tights-spheres with some cotton to bring out a more perfect 3D sphere look • Add more colors into the model to give it a better aesthetic aspect. • I could use some sort of cylinder with a controlled height to represent the base, which I could not manufacture due to lack of resources • I also realised the sphere-bulbs will not be sufficient in producing light, so I have decided to change the body material from wood to acrylic and place LED lights in it as well
  • 29.
    M.E.S.S Development I willbe using a lot of acrylic in this, so it actually makes my product really recyclable, because it can be melted and molded into different and new shapes and products Recycle Repair On the bottom of the base, there is a flap which opens and allows the consumer or the assembler to repair the battery socket or mains (which ever is being used) the spheres are held together by slots, so they can be opened and the LED lights can be repaired Reuse I could try and use the acrylic and woods from an old disassembled product, which would only make my product more efficient and environmental friendly, because there resources are not finite, and we lack the supplies. I could have tried and used glass for the spheres to give it strength in its function aspect, however I did not have the material (very opulent) and did not have the equipment to manufacture it. I could also have had used plywood, however it would not provide the same aesthetics furthermore, its very porous and can soak up water increasing density and mass of the product Rethink Reduce I would try and use the materials my colleagues have already used for manufacturing, as long as I make most of the remaining resources, and not wasting any, it will be as efficient in its production as possible Refuse I have used MDF rather than using mahogany or oak tree, because oak and mahogany are to difficult to manufacture and require immense energy, they are also a very rare and expensive resource to purchase, so this makes my product as efficient as possible Making sure my product takes the moral, environmental, social and sustainability issues as it is very important that it suffices all of these aspects I am going to use the 6 R’s to annotate my product. Introduction Sustainability? • My finished product is considered to be sustainable because the place where I bought my wood from is a sustainable resource, every time they chop wood off, they replant a tree • It is also sustainable because I used acrylic and MDF parts which had already been used by old disassembled products • My product is not sustainable because I used a lot of electrical CAM machines, which require heavy energy which is environmental damaging, which is against my specification • The paint I used cannot be trusted because it could be worn off through heat. • I could try and apply a paint adhesive which has high resistance to heat and radiation • Use only those machines which use less energy, and try to minimize their use in the making of my product Sometimes some products do not always fit in a market due to their cultural, moral or religious reasons. For example, my product has a Sci-Fi theme to it, which a lot of parents regard as the cause of brainwashing for teens and kids these days, which is why I could possibly have to face legal actions including prosecution. I would then possible have to remove the black color as well, as it portrays a theme of ‘gothics’ which is against or neglected by many people in the social community. Moral and cultural issues • How is it sustainable? • How is it not sustainable? • How could it possibly be more sustainable?
  • 30.
    Testing and Development Inmy first attempt to make the shape which will assist in the dispersion of the light, I had tried to make a sphere. To do that I created a drawing using my dimensions and then placed in the CNC Machine, which 3D printed the 4 pieces of MDF I had beforehand glued together using wood glue. After the 3D semi sphere had been printed, I found an issue with it, a part of it was damaged during the removal from the machine, which forced me to apply clay on to the damaged area to retain its spherical shape. After I had repaired the semi sphere, I placed it in the vacuum former, which was preheated having placed the HIPS. Once I got the shape of the semi sphere onto the HIPS, I had to remove the external edges and try it improve it aesthetically using the machine. However, in the end the process had not produced an aesthetically pleasing result, which made me disregard the manufactured, and I had given it to one of my colleague, as one of my criteria points is to be environmentally friendly. Method 1 (CNC/Vacuum former) Method 2 (Autodesk Inventor/3D Printer) In my second test method I used the Autodesk Inventor software to generate a semi sphere hollow from the inside with stars on the skeleton of the body in order to give it a aesthetical visual. After I did that I saved it as an .STL file. I then used a software called CubeX, where I imported the file and then printed out the 3D object, however in my first attempt I had gotten the dimensions incorrect, so I had decided to re-attempt the method, however the 3D printing machine had broken down for good, and our school was unable to repair the machine or provide me the color of my choice. So I had turned down this method as a tried, tested and failed! In my 3rd methods, I decided to try a different idea, keeping in mind that my client would accept either a sphere or a cuboid, I decided to fulfill that request. I used 2D design to draw pieces for the cuboid, with finger joints to certain dimensions, which allowed it to fit together. I then got them manufactured through the Laser cutter, and after that I used the solvent cement to glue the pieces together, after I placed the LED light within the holder I had drawn for it. This method prevailed because not only was it aesthetically pleasing but was also very technical and efficient Method 3 (Laser Cutter/Solvent Cement)
  • 31.
    Making Diary (thebody) To start of the making of my product, I used the machine which is known as the ‘circular saw’, and I used it to cut out 4 large pieces of MDFs with dimensions of 20 cm x 20 cm. I had to use safety precautions such as a plastic stick to move the pieces onwards, as using my hands would be a risk to my safety aspects of manufacturing this product. The reason I used a circular saw was because the MDF piece was large to handle with either a band saw or even a tenon saw, so to make the quality of the pieces was on top, I had to make this decision. After the manufacturing of the 4 pieces through a large MDF slab. I had to make 2 thicker MDF pieces because the single piece had thickness of 15 mm, which is to small, I needed a thickness of the body to be 6 cm, so if I can have 15mm pieces (x4) I can have 60mm of MDF, which is 6 cm, so I stuck two pieces together to make 2 30mm thick MDF pieces, I did this using wood glue, and made sure that I didn’t drop any glue anywhere else on the body or else it would give it a bad aesthetic view, to let the glue dry I had to attach 2 large size G-clamps and a medium sized G-clamp along with it placed in a vice on a table, this was done to make sure that the pieces did not move around changing the shape of the pieces from it required pieces, this was done to make sure the quality of pieces was on top I then took my prototype and placed it on the 2 thickened MDF pieces and drew out the outline shape of the product, to make it environmentally friendly and keeping the 6 R’s in my mind, I cut out the shape using the end of the pieces through a band saw, I used a band saw because it was the only thing strong enough for a piece like that which is holding dried wood glue, using a tenon saw would take me forever and would require more work done., I had to cut it out by using different angles to make sure the saw doesn’t go off lines. I had to makes sure to wear goggles and keep my fingers away from the saw. You can now see that I have cut out 2 30mm thick pieces of MDF like my template, this makes my quality as accurate a possible, because the template I used was my final design prototype, which was made through original dimension, you can now see the 2 MDF parts are equal and similar in sizes, and I will now sand them to ultimately glue them together using G-clamps, Vices and wood glue…….BUT FIRST SANDING! After I had my 2 pieces of thickness 30 mm cut out, I had to make sure that they both were symmetric to each other, to do that I had to make use of the belt sander, to use the belt sander I had to hold the piece on to the plate of the belt sander and push it on the belt, manoeuvring it along the process, for safety reason I had to place my had far away because the belt can cause friction on skin creating burns, and as well as that I had to use goggles to keep my eyes safe from the saw dust. Taking intervals was important to prevent excess inhaling of sawdust. 1 2 3 4 5 • Specification related • Machines and equipment's • Other methods and things
  • 32.
    Making Diary The beltsander brought some limitation which were that sometimes it was unable to reach certain areas due to the shape of the product, because of that I had to sand the remaining areas manually using my own physicality, took some time but got the job done. I had to tightly place it on the table vice and then sand it. I used a technique which made it a whole lot easier for me to sand and faster, I took a block of wood and wrapped some sand paper around it, and then I used it as a lever to sand the faces of the part, preventing any curves from being made which were not required. I had to take certain safety precautions such as making sure I don’t rub my fingers on the sand paper or cut splinters. I also had to take intervals to make sure I don’t inhale too much saw dust. After finishing I also cleaned up the whole area making sure that I leave no saw dust on the floor because that would be against my specification which says to be environment friendly. 6 7 8 After sanding down the whole body of the lamp, I had to begin painting it as a whole. To do that I had to make sure that the MDF was not soaking in any of the spray paint, in order to prevent that from happening I sprayed it with prima, which was a white coloured spray. I then let it dry for about 20-25 minutes, only to return and begin the actual painting. Before hand, I tested out how thick I wanted the paint coating to be on the wood, so I do not ruin it. I did a hit and trial method on multiple recyclable pieces of wood, until I found a perfect thickness. I then applied that thickness on to the body of my lamp. The thing about the paint I had used was that it was paint + prima, which gave it a more aesthetically pleasing view. I made sure that I did not inhale any of the paint and did it outside keeping in mind how toxic excess inhaling of spray paint can be. The second part of my lamp was the base. It was important that it was a base which would provide my lamp with the stability (as per my specification) it requires keeping in mind the excessive weight placed on the wings of my lamp body. So to do that, I went onto the Autodesk Inventor software and drew a 3D cylinder with a diameter of 23 cm and a depth 30mm. After it was drawn, I consulted with my teacher if it had was appropriate dimensions for production. After his nod, 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 15mm MDF I had previously glued together (wood glue) in to the machine. I then begun the process which took around 10-20 minutes. After it finished cutting, I had to manually complete it using the band saw machine, I wore glasses while carrying this out as well as under supervision. This is the bottom face, the cut passage from center through extrusion is a passage for the wires
  • 33.
    9 After I hadcompleted the cutting and the sanding of the base, I then moved on to the its finishing. Firstly, I made a hole through the center of the base using a drill machine, I did that while wearing googles and made sure that the object I was drilling was sitting there firm and steady. Once I had made the hole, I then placed the spackling on to the side of the base, while sanding it down with black sand paper, I then moved on to the painting part of the process. I took the base outside, placed it on an object not touching the ground and spray painted it red, the first coat I performed was left to dry inside, because if I let it dry outside then it becomes sticky, only to apply the 2nd layer of coating after around 20-30 minutes, the paint I used was really efficient because it consisted of prima and paint together. While I was painting I used a pluck to keep my nose closed so I do not inhale the toxins, and I made sure to do it outdoors away from plants and any other human 10 The 3rd object which was a part of my lamp was the object holding the light source. Now as you may know that I had planned to have spherical objects do that role, however due to the limitations such as lack of technology, equipment and others, I was unable to fulfill that part, however in my previous slides I stated the 2 method I had attempted to make spherical objects and how/why I failed. Also stating how the production of the cuboid became more efficient and aesthetically strong. I took this decision because my client had previously stated that he would be willing to accept cuboidal shapes as well, so as per my specification I’m on the right track. I first designed the 6 pieced cuboid on 2D design. 4 pieces for the sides, a top lid and a piece which slots between/inside the shape with a circles cut through as a place for the LED light to sit. I then used the laser cutter to cut the pieces out, the material I used was acrylic, blue color specifically as per my questionnaire, so that the light would be dispersed better, I made sure the suction was turned on, so I would not inhale any toxins 11 After the pieces had been cut, I had to start putting them together. To do that I had to first place together all the pieces and see if the finger joints fit. After my first try, the fit was perfect. I then began to put the pieces together. Piece by piece I glued together using Solvent Cement, a liquid which glues together acrylic/plastic. While I did that, I had to wear gloves, because the solvent was very irritant, and if was poured on my skin, I would have an issue. I poured the liquid into a cup, and used a paint brush to spread the solvent through the edge. Before gluing the lid, I placed the LED light into the cuboid, with its bottom pins facing the lidless end, where it will be connected to the wiring. I did the same and created another cuboid, because I required 2 of light source holding objects. 12 Once all the pieces had been made, wiring had to be done. The 2 live wires had to be joined through welding, while the 2 neutral wires (blue) did the same, and the green wire (earth wire) was together from before, and we then screwed them in to a mains While using the welding tool, I wore gloves to prevent burns also we had a wool mat to cool the metal end down.
  • 34.
    13 Once the wiringis done, the next and final part is putting the part together with the wiring connected. First I placed the wiring between the 2 body pieces only the glue them together using wood glue. I then send the wire through the base which places the whole body onto the face of the base, to make sure it stick there, I placed some wood glue underneath the black painted body. I then connected the wirings with the LEDs in the 2 acrylic cuboid, while once again going over the edges of the box with Solvent Cement. Once all of the things were put together, I then decided to plug in the main, but I made sure that I was plugging it in a switch which was turned off, because a short circuit could cause fire, and once I placed it in and turned it on…….. Finished!!!
  • 35.
    EVALUATION AGAINST SPECIFICATION/QUALITY CHECK Function • It should provide sufficient amount of light for reading or studying • It should be portable anywhere around a room • The on and off button must be working flawlessly  The mains switch works great, with the wiring is perfect and strong Aesthetics • My product should follow my Sci-Fi/Space theme  Has a Sci-Fi spaceship look • Lamp should not have any bird edges, or anything that makes it look messy • It must have majority of the colors which were chosen in the questionnaire  3 colors (blue, black and red) highest polls • No rough edges of the wooden base or any dripping paint be visible to the costumer  Well sanded using belt sander and sand paper Safety • It should not have anything pointy sticking out of it, because my product is basically for teenagers, who make harsh decision very quickly • It should be in a state where it doesn't falls of anywhere it is kept, because if it consist of glass, then it will shatter everywhere  The cylinder base makes it very stable Size • As the majority of my clients stated that he/she wanted a height between 30cm – 50cm  My lamp had a height of 45cm • Must consist the shapes which were chosen at a majority between the 50 people such as a sphere or a cuboid Customer • Its mainly for people between the ages of 10-20 (adolescents)  The color and shape is attractive to young aged people • For people who are into the Sci-Fi/Space theme • He should also have interest in mechanics, technology and modern looks  Has wirings and LED light which look like Iron Man’s chest piece Material • As I went into further detail in my research on materials, I found out that the best wood to use was either plywood or MDF, because they both can be used for good finishing and drilling in bolts, nuts and screws. • Acrylic would be a better option than other sort of plastics or even metals, because they require more effort and machinery • Bolts and nuts should be reduced as possible as they can fracture the material or component • LED is the best option as it was the major choice in my questionnaire and it has the most advantages Ergonomics • The average size of a human thumb is between 2.75-2.49 inches, that’s how big the on and off button should be  The mains switch is based off that Cost • After my client interview, he/she was willing to pay 60 pounds for my product, which covers my cost and gives me a 20% profit Environment • My LED lighting should release the least possible waste energy (heat) • I should be as efficient as I can be when consuming my resources at hand. • I found out that the product must be as efficient as possible using up less energy, not wasting any resources and not pollute the atmosphere through emitting toxic gases Manufacturing • Try my best to impose as many techniques as possible such as vacuum forming, 3D printing, CAD/CAM, Laser Cutting, Sanding machine, Band Saw • Must use more finishing techniques to clear things such as bird and rough edges • It should be simple and efficient to assemble and disassemble the lamp  Only 3 pieces are required to be joined, the others have finger joints to make it easy • Achieved  Explained how? • Moderately achieved • Failed
  • 36.
    Evaluation- Opinions Where wouldyou place the lamp? Bedroom Living Room Garden 4% 10% 50% 20% 16% How much are you willing to pay? £40 £50 £55 £60 £70 70% 16% 14% What aspect of the lamp is your favorite? Light source holder (cuboid) Body (black) Base (Red) 20% 80% Would you buy the lamp? No Yes 4% 80% 16% What aspects needs improvements? Light souce holder (cuboid) Body (black) Base (Red) 100 % 0% Does the lamp embody the theme? Yes No • The body could be a bit more symmetrical to the other piece of the body. • Another layer of paint would have helped. Popular suggestion Favorite things about the lamp • Embodies the theme • Looks well finished • The design is very simple and easy to assemble • Easily portable • Looks really stable, even thought a design such should be very unstable. How would to improve it? • First thing, I could further sand the body as a whole, to get the better symmetrical shape which was being brought up by the buyer • Also I could put on another layer of the prima + paint I had used.
  • 37.
    Modifications • A wayto improve on the size would be avoid having aspects of the body so thin, vulnerable to damage. • Try to have a better aspect ratio of sizes between the parts of the lamps Size • I could next time try and actually make prototypes of every single part before actually starting production on the real parts. • Try to be as efficient with the resources (such as paint, acrylic, and wood) as possible Environment • Try and improve the balance in the paint layers applied onto the parts of the lamp • Use an alkaline solution to remove the marks left by the Solvent Cement. Aesthetics • I could have sanded all the edges to make them even more safe for the user. • Rather than acrylic, I could’ve used a metal which would require a lot more force to crack than plastic Safety • A more clear show of the function of the black painted body. • The middle part in the body could have also consisted of a light source to produce even more light Function • I could make is more consumer customizable, like I could have different colored acrylic cuboids, which would disperse different lights. Customer • Instead of acrylic I could have used a metal which is way more strong. • I could use stronger LEDs to have stronger light dispersion Materials
  • 38.
    Evaluation- improvements + overcomingproblems + Factory Production Factory/Mass production 1. The top acrylic boxes are produced through drawing of the pieces on 2D Design, being produced through laser cutter, so this shows how cheap it can get, because acrylic is not that rare, and is really cheap to buy, so you can but it in a large amount. 2. The base is manufactured through using the CNC Router after it was drawn on Autodesk Inventor, MDF is not that expensive and is very easy to manufacture, also sanding it is also very easy, which means that finishing of the base would not take that long, time and work load efficient. 3. The wiring used in the lamp is very basic, with the red live wires coming from the LEDs are connected together as well as the blue neutral wires while the brown/green earth wires are left separate, basically a structure of a mains mechanics which is cheap and heavily available due to it mass structure. 4. The body is the only thing which can take time, however, having the MDF cut in big bunches will allow more time to be saved, perhaps the cutting may not be as good, but remember that its MDF, which is easily manipulated through sanding machines. 5. The LED lights are in mass production already and are cheap to buy in bunches, keeping in mind that these are the best kind of light source, because they do heat up as much as filament bulbs. 6. This shows that this lamp can be produced at a large scale. On the first layer of the paint I had sprayed, I left it to dry outside underneath the sun, keeping in mind I had used black paint, it heated up, as well as became a bit sticky, so I had to bring it in the air-conditioned room to cool down only to reapply the paint Painting Issue Body Cutting It was really difficult to cut the body of the product, because of its irregular shape, using a band saw to go through such sharp turns was difficult, so to overcome such issue, I had my teacher give me a tutorial by cutting the 1st of the 2 pieces himself, and then I had understood how to do it, my attempt was 99% similar Problem + overcoming the problem