Case Study: LED Work Lamp

Case Study: LED Work Lamp

Program Management

Industrial Design

3D Development

Project Brief:Hamsar is a Toronto based producer of lighting for the aftermarket, marine and heavy equipment industry. While working at Tiger Studio, I was asked to design a light that would fit a product niche in Hamsar’s LED offerings. The LED design that was developed was to be used in heavy equipment applications including coal mining rigs and front end loaders. Its versatility made it easily adaptable to four wheel vehicles, off road vehicles, trucks and long term lighting usage situations like walk in refrigeration environments.

The design criteria included:- Versatile mounting- More aggressive/rugged appearance- Unique look in the market- Plastic bezel and metal shell construction- Ability to support various LED configurations- Heat sink capability built into the design

Meeting all these criteria - the design was released in the fall of 2008 and has been a strong seller for Hamsar.

Printed with permission by Hamsar

Research: Competition

The Competition included a wide variety of shapes and assembly methods. For the most part LED designs were basically looking like incandescent designs. This was because the competition was retrofitting existing housings with LED assemblies. There was nothing special about this at all

Research: User/Industry

The End user of the lamp was hard working and the new design needed to reflect this. Also the environments it needed to work in was extreme and harsh. The new design needed to be able to take a beating.

Research: Related industries

Related industries could be viewed for new features and novel ideas for utility. Function, adjustability and design form cues can be derived from looking into this research category.

Research: Inspiration

Rugged Iconic forms from other industries lend inspiration to what was to come in the Concept phase of the design process.

These “wrap around” sandals were the inspiration for several of the designs explored in

the Concept Phase

Concept: Initial ideation

Rugged Iconic forms from other industries lend inspiration to what was to come in the Concept phase of the design process.

The “wrap around” sandal inspired the majority of concepts including the above shape that utilized the look of the wrap in the mounting scheme.

Concept: Initial ideation – 3D

3D concepts for lens treatments and overall form

“3D” lens forms added interest and boundaries for the placement of LED’s for spot and flood applications. Non essential areas of the lens would be textured for minimal see through and to add clean appearance characteristics.

Refinement: 3D concept surface creation

Final form derived from the wrap around look in the concept phase. Details taken from previous designs were built into the look, like the four bullet shaped mounting positions of the front bezel to the back housing heat sink and the four bracket mounting channels for multiple mounting scenarios.

bullet shaped mounting bosses.

four bracket mounting channels

Color and material studies

Refinement: 3D concept surface creation

The “Turbo Fan” back case is a massive cast metal heat sink that also portrays the rugged look that we were going for in the design. It adds a weight to the light and impresses owners as a very durable design.

Refinement: Final Surface Release and Photorealistic Rendering

Production Design –High output version

Finalization: Production Release

Production Design – Marine Application

On line sales fliers

Shown in an off road vehicle application.

Contact Information

Bazza Design LLC

Barry Hutzel – Principal / Owner

2058 Breeze Drive Holland MI 49424

www.linkedin.com/in/barryhutzel/

barry.hutzel@bazzadesign.com

bazzadesign.com

616 335 0219