IVALO Lighting ME 597B Designing Product Families

1. IVALO LightingME 597BDesigning Product Families

2. Presentation Overview • Introduction • Sponsor Background • Project Goals • Project Foundation • Product Design Strategy • Manufacturing Strategy • Course Relevance • Conclusions • Future Work

3. Introduction • Objective: • Investigate the customizability of a hanging light fixture for kitchen, home, and office use. • Develop CAD models and CNC machine prototypes in the following hull sizes: 3,4,5,6 ft

4. Sponsor Background Source: Cornell University - School of Electrical and Computer Engineering “Dr. Hakkarainen is the founder of Ivalo Lighting Incorporated, a company that will produce premium decorative light fixtures for the residential and commercial market. Ivalo fixtures use cutting edge technology to produce advanced, high fashion designs that have superior optical properties and quality while maintaining ease of installation. Ivalo will feature designs from all over the world and is starting with Italian designs.”  SUSAN HAKKARAINEN President,Ivalo Lighting Incorporated

5. Project Goals An inexpensive and durable model is desired for display and design purposes. • Develop a family of products ranging in size from 3-6 ft based on the original 4ft model. • Use knowledge gained in Designing Product Families to create products that exemplify scale-based product families.

6. Project Foundation • Ivalo provided an original 4ft prototype • Original drawings for the prototype shape and other parts were also provided. • Phone conference with Susan Hakkarainen outlined design requirements and changes.

7. Product Design Strategy • Proportional Axis Scaling • Non-Proportional Axis Scaling • Attribute Scaling

8. Product Design Strategy Dimensions in inches Revolved cross section R H L Attribute Scaling Method

9. Product Design Strategy canopy Why Use Attribute Scaling Method? • Canopy, hull and center chassis are unique for each light. • Supports and end chassis are identical for 3 & 4 ft or 5 & 6 ft models • Grill discs can be used for multiple lights (3 & 4 ft or 5 & 6 ft models). grill supports chassis hull center chassis end chassis

10. Manufacturing Strategy How Do We Make It? • Find an inexpensive material that can be machined easily, that is cheap, and that is durable. • Plastic (PVC), wax, wood, metal • Determine a quick and easy method for making the parts. • Machine using CNC machine, or Lathe • Make mold, final product (shell) or solid block

11. Manufacturing Strategy 12 Step Manufacturing Process

12. Manufacturing Strategy

13. Manufacturing Strategy

14. Manufacturing Strategy

15. Manufacturing Strategy

16. Manufacturing Strategy

17. Manufacturing Summary

18. Course Relevance How does this project tie into the class? Course Question: How can product realization teams provide increased product variety at less cost for a highly competitive, global marketplace? IVALO Lighting Answer: Designing (scaling) a product carefully can allow manufacturers to create multiple products using common parts and take advantage of economies of scale.

19. Course Relevance Source: ME 597B (Designing Product Families) - Scalable Product Platforms

20. Conclusions • An overall shape was designed for the 4ft. model. • The design was scaled by scaling different attributes of the structure • Molds were machined using CNC machines • Fiberglass and Bondo were used to create 3, 4, 5, and 6 ft models.

21. Future Work • Create remaining parts needed for working prototype: • Canopy, Grill, Chassis, Support • Redesign for Aluminum (if needed)