5 weeks · product, lighting · fall 2023
Say hello to Gelli.
a textural night-light created with biomimicry design principles.
Initial sketching explored tactile, hard-surface concepts with focus on user interaction and features.
Although the features were engaging, the initial forms needed better inspiration.
The final aesthetic direction attempts to combine all previously explored concepts into one cohesive theme.
Thumbnail sketches exploring the new aesthetic direction with focus on silhouette, light placement, and textural elements.
Constant feedback enabled more creative iterations and a more successful overall design direction.
Key takeaways from peer critique included:
Concerns about LED location and brightness
Issues with switch/button placement
Continued exploration on textured elements
Foam and paper models were used to quickly explore the most effective iterations in 3D.
Each model was evaluated for scale and button placement, and informed concept refinement decisions.
The final visual concept with explorations for how to construct the necessary mechanical components.
Many lamps utilize rotary switches, which are difficult to operate in the dark and can cause the user wrist strain.
The proposed solution a is large button on the top surface of the lamp which can be easily activated in a low-light environment with minimal wrist strain.
Most CAD modeling was done in Rhino for its surfacing tools.
On average, 10-15 iterations were made for each part.
Regions that needed tolerance for electrical components were blocked out but not refined at this stage.
In early prototypes, the lamp baseplate was a single, solid 3D printed piece. Later, it was expanded into an assembly, enabling injection molding.
The lamp was prototyped from 3D printed PLA throughout the design process. At first, prototypes were used to validate silhouette, form, and scale. Later, they were used to make design engineering changes and test for manufacturability.
A mold of the dome was 3D printed and used as tooling vacuuforming. Test versions of the dome were created out of HIPS, but the final prototype version is made of PETG.
In order for the vacuuformed part to release from the mold, draft angles were added to the design in
CAD.
Button cap
injected molded polypropylene, colored
Upper rim
injected molded polypropylene, colored
Inner tube
injected molded polypropylene, clouded
Outer dome
blow molded glass, clear
Scalloped tube
injected molded polypropylene, clouded, requires additional tooling
8mm LED
sourced
Spring-loaded buttons
sourced
Tech plate
injected molded polypropylene, clouded
Base plate
injected molded polypropylene, colored
AA Batteries
user-provided
Battery Door
injected molded polypropylene, colored
4-40 3/8 machine screws
stainless steel, sourced
The final functional model is a result of 12 prototypes and user validation research.
It uses two AA batteries, is 3D printed from PLA, features a functional, tactile switch, and transparent, vacuuformed PETG outer dome.
The final concept render, created in Blender, showcases Gelli's functionality and persistent beauty across various light levels.
Many challenges were overcome throughout this project, resulting in several takeaways that will be applied to future design projects.
Learning how to properly transfer files across softwares and when to use each enabled more efficient design. Rhino was used for compound surfacing and Fusion360 was used for design engineering.
Designing a functional, multipart assembly increased understanding of tolerances and designing around stock electrical components.
Designing for manufacturing increase knowledge of draft angles and ribbing.
