Logbooks Lamp 25CMLED
The design of lamp 25CMLED has already some history. The lamp was originally designed for the first LED Workshop where workshop participants had to solder SMD LEDs by hand.
For the new LED workshop, lamp 25CMLED will no longer consist of individual LEDs soldered by hand. Instead lamp 25CMLED will be powered by three LED modules: Module 1.
The original design of the 25CMLED lamp evolved during an online design course. All the course material can be found here. The course material should give you a good idea how the design evolved.
The main outcome of the design course, was the design for a 3D printed lamp grip. The lamp grip can be downloaded at thingiverse.
The feedback of many LED workshop participants was that they do not have access to a 3D printer. Also creating the grip by ordering it at a 3D printing service was no option for many workshop participants due to high costs.
Therefore the current 25CMLED design project has two main goals:
- come up with a grip design that can be quickly manufactured using a laser cutter
- adapt the 25CMLED design to use OpenLedModule Module 1
- Cardboard prototype done
- First lasercut MDF prototype done
- Improved MDF prototype in progress
To get a feeling whether the grip for the 25CMLED lamp is doable with lasercut parts, I did a quick prototype made of cardboard.
A cardboard prototype of 25CMLED
The cardboard prototype gave me a number of insights:
- The housing including the battery package still fits nicely on the aluminium profile.
- It should be possible to integrate a switch in the grip
- It should be possible to integrate the Switch cable into the grip
- The grip slides nicely into battery housing while still providing enough stability
Detail: Battery housing
Detail: Integrated switch
The lasercut prototype should show that my assumptions of the cardboard prototype are still valid when using wood (MDF). For the first prototype, I had not enough time to draw all the required holes, therefore I had to drill a few of them by hand.
A lasercut prototype of 25CMLED
The lasercut prototype gave me further insights
- The stability of the housing is sufficient when using 3mm and 5mm MDF
- There is enough tolerance in order to slide in or slide out the battery package
- The space for the cable in the grip is sufficient
- The stability of the housing and the grip seems to be sufficient
- The positions of the holes in the aluminium profile might be reusable (i.e. participants of my former LED Workshops might also mount the new lasercut grip to their lamps)
- It was probably a good idea to make the bottom of the battery housing out of two 3mm layers of MDF (instead of using just one bottom layer of 5 mm MDF). Reason: with two layers, there is no need to sink the hole for the screw head. This results in one step less for the workshop and speeds up mounting the housing.
Detail: Cable in grip
Detail: Battery Holder
Detail: Holes for mounting the housing to the aluminium profile