1. IOSI
was
given
the
opportunity
to
develop
a
LED
flood
light
for
the
builders
hardware
market.
The
customer
provided
performance
specs
but
leA
the
design
open
for
interpretaBon.
AAer
sketching
out
an
iniBal
design
concept,
IOSI
assembled
a
team
that
could
provide
the
needed
experBse.
Team
members
included
companies
with
the
following
skill
sets:
3D
Design
PlasBc
Rapid
Materials
Prototype
Color
Design
&
LED
Final
Design
Finish
LED
Flood
Light
Vacuum
Final
Metal
Assembly
Die
PlasBc
CasBng
Molding
2. Solid
models
of
the
iniBal
design
concept
were
needed
to
facilitate
team
3.99
discussions.
IOSI
engaged
the
3D
Design
House
and
began
to
create
digital
renderings.
During
the
back
and
forth
process,
design
elements
and
features
were
added
and
a
final
design
began
to
emerge.
In
an
effort
to
confirm
customer
performance
specificaBons
were
met,
a
3.99
working
light
engine
was
built
and
evaluated.
2.99
3.99
2.99
3.99
4.68
2.99
3. AAer
a
design
review
with
several
of
the
involved
team
members,
accurate
renderings
could
now
be
craAed.
In
addiBon
to
the
light
housing
itself,
a
mounBng
system
had
to
be
developed.
Part
of
the
original
commission
was
to
develop
a
product
that
could
be
manufactured
and
assembled
in
the
USA.
ReducBon
of
components
and
labor
heavy
processes
were
major
consideraBons.
4. !!!!!!!Concept!for!Plug/In!LED!Lig
!
!!!!!!!!!!!!!!!!!!Design'Elements'
serpen7ne!design!on!fins!for!both!
style!and!increased!surface!area!!
The
design
had
evolved
to
the
point
we
could
now
solidify
esBmated
costs.
One
of
our
main
objecBves
was
to
design
a
housing
that
could
be
easily
finished
in
convenBonal
powder
coaBng
along
with
“Lux
Liquid”,
PlaBng
and
3D
decoraBon.
The
simple
two
piece
design
would
allow
us
a
wide
range
of
final
finish
opBons.
•
logo'printed'from'inside'of'lens'
•
The
FDM
process
was
used
to
“print”
an
actual
scale
part
for
aluminum'die'cas4ng'''
use
in
final
design
review.
•
hard'coated'lens'is'captured'by'cas4ng' •
'
'
''
opBon
port
cord
port
hard
wire
port
5. IOSI
had
the
final
design
rendered
in
different
looks
showing
product
differenBaBon
opBons.
