e portfolio final

Anthropometrics

Client

Finishes

Manufacturing

Art movements

Materials

Lighting

ErgonomicsSize

Maintenance

Colour Shape

Adhesives

PVAEpoxy resinTensol

Denford micro router CAM 1 CAM 2 Laser cutter 2D Design

Q&C

QUALITY CHECKSTESTINGEVALUATION

Vacuum formingCastingAnnealinglaminating

Process

Art Nouveau Arts and craftArt decoBauhaus

Varnish Paint Dry pigments Clear lacquers Stains Veneers

NeutralVibrantPrimarySecondaryPastel

FunctionExports featureExports lightShows decoration

lighting

Bulb lightCircuitLed’sPCB’SPower supply

Mum-Miss Briggs

Size depending on anthropometrics

Comfort and easy for use Switching lights on/off Changing light bulbs Correct size

GeometricsquareCircularTriangularFree flowing

Design brief

My mum is currently redecorating her house because she wants to make the decor look more up to date. In addition she wants to create a unisex interior that makes her feel more relaxed after a hard days work.At the moment she doesn't have a lot of different lighting systems that would create subtle illumination that would complement this mood.It is my intention to design and manufacture lighting that will enhance and complement her decor.

Task Analysis:

Having conducted this task analysis, I intend to research relevant primary sources. This task analysis will assist me in decision making , planning and manufacture of my the potential product.

FingersHandsHeight

Possibly for BedroomLiving roomKitchenBathroomhall

Portable or Stationary

Renewable energy sourcesUse of cuts where possible.

Health and Safety risks-No sharp Objects/corners-Eu standards

Mood BoardsSpecific clients’ needsFurther specificationfor the products needs.

End of manufacture

During manufacture

Conclusion

This design brief allows me to discover my clients needs and desires in order to produce a product that is suitable In this design brief, it allows me to see what I have to do to satisfy my clients desire and to produce a product that is not only suited for them, but to the quality best for them.

KEY: Primary Research Secondary Research

Easy to clean/dustBulb needs changing often.

VisitsMuseumsGalleriesTrips

Reliability

Existing products Lighting in the house/rooms Lighting in storage Lighting in different shops

Location

H&S

Hardwood

Softwood

Man made board

plastics

metals

beech, Oak, Mahogany, Teak and Balsa

Cedar, Fir, Silver Larch, Pine, Redwood, European, Yew

Plywood, chip board, MDF

acrylic

Copper, AluminiumCopper, BrassIron, Steel

Sustainability

Product Purpose Function Market Materials Finishes FittingsFixturesFindings

Size Weight Quality Standards

TrendsStyles

Environmental Issues

SocialCultural

Performance H&S Aesthetics Cost

To offer a small amount of light on a side table.

The product illuminates a miniature part of the room for observational uses.

The product is quite plain with neutral colours, it is unisex.

The product is manufactured from pottery with a glaze finishing. The shade is constructed using a calico material.

The finish for this product has used a glazing for a smooth surface and an attractive look, the shades has used calico which is also covered a flame retardant finish.

The lamp uses a screw in holder for the bulb which is then attached to the body of the lamp.

The product is relatively large is its length and width.

The product is lightweight in order for it to be portable.

The product has gone through a varied amount of tests in order to identify faults and demand them before the product can be sold.

The simple lines and shape of the product with neutral colours appear organic.

The clay had to be sourced from the ground and processed into a useable material. The glaze is none toxic. The calico is a recyclable material

Because the light is organic in shape it contains no offence of imagery or symbols.

Due to the large base and light calico shade, the light is well supported and stable.

The product is very stable so it is unlikely to fall over. It is not sharp to injure the client and it is flame retardant to ensure safety.

The lamp is quite minimalist. However the glaze is fairly desirable.

£29



The products sophisticated style would attract an older generation of client. However this product could easily be unisex.

The product is constructed out of aluminium for the frame, the shade is made from calico material. The switch is made from a nylon cord, the beads are from the same material as the base.

The product has a chrome finish on the frame of the product. The calico shades has been treated with flame retardant chemicals.

The product uses a screw in holder for the bulb which is then switch on via a nylon cord then decorated in small but stylish beading.

This product is roughly 70 cm high and is slim in width.

The product is lightweight in order for it to be portable.

The product has gone through a varied amount of tests in order to identify faults and demand them before the product can be sold.

The products shade uses a delicate folding technique to make it aesthetically pleasing. The frame of the product uses a modern finish towards the base that would compliment any room.

The aluminium has to be sourced from the ground and processed into a useable material. The chrome finish is none toxic when the product is sold. The calico shade is a recyclable material.

This light displays no violent or offensive symbols .

The bottom of the base is slightly heavier because it is to bring balance to the product. The cord is a nice and easy feature. The calico shade is fairly light and is well supported.


The product is quite simple in its ways of appearance. However the calico shade features a folding feature therefore making it appealing to the client.

£23.99



The products recyclable style attracts a younger audience.

The product is constructed from recycled glass bottles with cork bottle tops.

The product has a different finish on each glass bottle. 1- Ombre dye effect2- gold leaf3- recycled glass

The product has a drilled hole in the base allowing for the light to be interchangeable

The product has 2 bottles that are 25cm in height and 15cm wide while the other bottle is 30cm high and 15cm wide

All three products are lightweight and are easily portable.

This product has been tested for heat but no further tests have been conducted before retail.

All the different colours within the product are aesthetically pleasing along with the mood lighting feature to change the atmosphere of the room.

Its all recycled glass so therefore it is better for the environment.


Because of how wide and short the product is. It makes it more stable.


The product is rather interesting in its use of different size and coloured glass bottle that are combined in order to make a light that can be rearranged to fit the consumers needs.

Free due to recycled materials

Product Analysis -Primary

-Secondary

Product AnalysisTo offer a small amount of light on a side table.


This products shiny finish and touch sensitive ability attracts the younger audience or people who like advanced technology.

This product is constructed from a thin aluminium layer and glass.

This product has a high chrome polished finish with a thin clear glass cover.

This product has cut hole out which enables light to pass through the product to give the area a sufficient amount of light.

The product Is touch sensitive, with 3 touch stages (low, high, very high) it is 30cm in height and 19cm in diameter.

This product is lightweight and easily portable.

This product has been tested for heat to ensure that glass does not burn the user when changing the brightness of the light.

The product uses a series of brightly white/yellow colour embedded lines by the cut holes where the light shines through along with the randomly shaped holes as well to give the product a complete natural organic look.

The glass was formed from sand and the aluminium was bought from a supplier.


The product is all around lightweight, the spherical top end is however slightly more heavier than the base due to it containing the light source and it being larger than the base.

The product is well constructed with a thick but lightweight stainless steel base that is equipped with a rubbery sponge soul at the very bottom which stops any damage being caused to any surface.

The fine lines surrounding the cut out holes give the light an organic look following the high chrome polish making it aesthetically pleasing. The spherical shape giving the product a sun/moon like look this then making it more desirable for people who like astronomy.

£35



This products well polished finish and copper strand from top to bottom give this an edge towards it being for a unique audience who like random designs.

This product is constructed from thick copper strings.

The product has a well polished finish on each strand of copper.

This product has large open gaps that are between the copper strings, this then gives the product enough room to light up the area it has been assigned to.

This product Is 40cm in height and 30cm in diameter.

This product is lightweight and easily portable.

This product has been tested for heat to ensure that the user does not sustain burns or heat injuries from possible overheating when the light is on.

This product has a series of well polished copper strands going from the top to the bottom of the product which gives it a natural tree branch/vine aesthetic look.

The copper was bought from a supplier.

Because the light is organic in shape and style it contains no offence of imagery or symbols.

the product overall is rather heavy due to the thick copper strands from top to bottom of the light.

The product is very stable due to the thick base constructed from the thick copper wires, therefore it would not fall over then becoming a possible hazard to the client.

The copper strands connecting from top to bottom give the product a natural tree/vine aesthetic look making it more desirable for people who enjoy the outdoors/nature.

£25

Conclusion:From my primary research I have found out that the range of finishes that have been commercially used were very aesthetic and visually appealing for example, the chrome finish on product number 2. This finish conveys a modern feel that is very much on trend and is often viewed as classic. In addition, products 2 and 3 give illumination that is very soft and glows this adds ambience . Finally, I didn’t like many aspects of product 1 because it’s so basic. I did, however, learn from this and I will aim to include a lot more detail in my proposed design. This is because my client prefers more decorative pieces that a make a bold statement.

Client profile 1Sandra Briggs is age 47 and not married. She has one child, whom is living with her. She works in Superdrug located in Moreton as a sales assistant. She normally does about 20 hours or more in a week and once a week she does delivery early in the morning and once a month she does promotion changing late at night.

Sandra’s favourite colours focus on some metallic pinks and purples, and some of the basic shades of green (Light-dark). Her favourite theme is floral suitable because of the outdoors and how she enjoys the scenery.

Sandra loves the scenery outdoors and loves walking to an outdoor pub/restaurant in the countryside to then have a meal and enjoy the fresh air. In addition she also loves to relax and read her books when she has time, also she likes to be able to sit down in the cinema and watch a good film. Although she is currently having to do a lot of indoor work at her house because she is redecorating her Hall, living room and bedroom.

Sandra (my client) Is not very interested in artists, she does however enjoy looking at art she finds fascinating for instance, fine line drawings or very intricate pencil drawings with detailed shading. She would like shapes of the natural forms such as trees without leaves, or mountain organic forms and mountains included on the design of the product since she would like it to look very free looking and “pretty”.

Sandra Briggs

Conclusion:The client profile permits me to comprehend my client to perceive her likes and dislikes that enables me to design and make a product that best suits the client so that he/she will be pleased with it. It authorises me to get a sense for he/she even more beyond his/her adequate opinions.

Here is an image printed on canvas that my client particularly likes and is hung upon a wall in her living room. This is an organic photograph of a forest somewhere around the world. It is over 6 years old.

Likes Dislikes“It makes the atmosphere feel chilled, the picture is quite peaceful.”

“There is nothing I dislike about this image.”

“It feel it is a good size and fits the wall well.”

“The colours go well with the room and the greens and yellows are very calming and I like how the sun shines through the trees.”

“I wanted a calming and relaxing picture that I thought was different than the other pictures that either included people in it etc.”

Client profile 2This is an image my client has got hung up on the living room wall. I felt it was a very good idea to use for the start of my clients product. This image included a split image using a wooden frame with a canvas on top. The idea of the image split across 3 separate panels adds more interest to the art work because each canvas could be used as a stand alone image if required by the user. This makes it a far more versatile product, however, some may argue that splitting the images up would affect aesthetics. This met my clients tastes due to it already having relevance to this image.

Wooden frames with a canvas on top.Canvas with daylight sky and

natural mountain theme.

Likes (client) Dislikes (client)“I like it because it is split into 3 segments and the concept of it is pleasing.”

“No dislikes about the picture hence why I have it on the wall.”

“It’s a relaxing and peaceful image on the canvas.”

Materials: Pine (for wooden frame), Canvas (stretched to fit tight), Paint in which it is has made the image up. It is over 4 years old.

This picture was a gift from a close friend, the reason I decided to hang it on my wall and not get rid or decide against putting it up was because I really liked the look of it and I felt it matched with the theme I was going for in the room I was decorating.

Conclusion: I conclude that this image is a very important to my clients . I and my client like the segmentation of this image very much and we think that the natural, organic mountains are very calming and promote relaxation. Taking all of this into account I’m going to incorporate organic forms into design ideas for my client to appraise. I will then be able to design a product that meets with my client’s approval.

Reflection of mountain in water.

Client Questionnaire• For certain questions I felt that the answers my client gave to them

question played a very big part in the creation of the final product as it revealed a lot about what my client likes and dislikes but also a personal touch as well. these questions were…

• “what is your favourite colour(s)? ( you can select more than one)” this informed me as to what colours I could include in the creation of my clients product.

• “what are your hobbies and interests?” to this my client added “scenery” to her interests, this and the previous question on colours made me realise that using natural and organic features such as mountains and trees and different shades of green and purples.

• “What design would you prefer your lighting/storage product to be for?” this my client answered with low lighting and natural forms. This means that the use of natural scenery is a must include in the product.

• Finally my client answered to the question “What materials do you mostly desire?” that she would like “Wood, plastic and fabric” to be used for the final product.

I have done this client profile to analyse the key questions in my questionnaire to my client, this gave me an even further accurate reading on what my client may like/want the product to look like or incorporate. , for example, my client specifies that she likes natural forms.

Mood board analysisIntentions Client/target

audience views and feedback

Conclusion Further Intentions

Having finished the colour mood board, I have now produced and demonstrated a variety of shades from the 3 colours that I collected information throughout the questionnaire, as well as the natural forms. Including some shades of green (Light-Dark). I am looking forward as to what my clients opinion on this is because I will be showing this mood board to my client. I am eager to know my clients likes and dislikes along with the specification of what colours my client wants precisely looking for with regards to the lighting.

After presenting my mood board to my client along with offering the option to express their judgement. I found that my client was interested in the large variety of different natural forms such as trees, mountains and landscapes.My client particularly liked the layering of images spread across the page. If I were to apply this to my design it might benefit the product as my client would be more likely to buy this product. In addition this particular design would make my product eye catching and appeal to a larger target market.

After collecting my clients opinions and feedback I have concluded that the natural forms of autumn trees and the vibrant colours that my client is particularly partial to would be best suited for the finishing product.

I intend to create series of designs that are tailored towards my clients best interests. In order to do this I will focus on the natural forming of autumn trees and vivacious scenery that my client has revealed interest in.

Conclusion: I conclude that my mood board turned out better than I expected, this being because I used a multiple series of pictures that my client likes and would appreciate when thinking of colours/designs that of the product that is being created for her. I will be able to refer to my mood board during generation of ideas and development with regard to organic imagery, colour scheme and so on.

Anthropometrics/Ergonomics

Conclusion:After analysing my client’s range of movements one of the key factors is to limit the amount of stretching that my client has to do for example, I will endeavour to produce a product that doesn’t require my client to over reach or stretch when she might be changing batteries. In addition, I will being trying to incorporate switches that are easy for my client to turn on and off probably by using her fore ringer (sliding switch or rocker).

Here I have taken measurements of my client’s hands, arms, fingers and height. I have also taken measurements of my client switching off a light and holding a plug. This information will enable me to see to what extent that my client can move comfortably without causing injury whilst performing each task. I can see that she doesn’t experience any problems when she is switching on the light by using her fore ringer. In addition, I wanted to establish what sort of pincer grip she had and whether or not she found this particular movement easy to perform. The idea being that there may be components, within a potential product, that she would have to grab using a pincer grip. Finally, I asked my client if she could change a light bulb without straining. She managed to perform the task but said that she had to stretch over the light shade in order to get her hand to reach the bulb. I can see that this is not an ideal situation and is something that I want to avoid when designing and manufacturing a potential light.

• Arm- 48 cm long

• Perimeter of Arm:

• Upper 23cm/10inches

• Lower 19cm/8 ½ inches

• Height- 5ft 6 inchesClient removing old light from previous light/lamp.

This is a close up image of my client turning off the living room lights.

This is my client posing with her hand as a pincer grip.

Ergonomics

Here is my client attempting to take the light bulb out of the lamp holder.

-Primary

-Secondary

Good Points: Bad Points:Why: -My client was able to gain access to the light blub without straining herself in any way.-Whilst my client was taking and replacing the bulb she was able to unscrew it safely without causing injury.

Why:-My client had to stretch slightly over the lamp shade to gain access to the light blub to replace it.

-My client was able to gain quick access to the shade connectors without causing strain to herself in the process and remove the shade from the lamp.

-Again my client had to stretch herself over the lamp shade to gain access to lamp connectors to detach it.

-My client was able to quickly and easily replace the light bulb without struggle. Screw in and out bulb holder.-My client did not have to stretch over the lamp therefore causing no strain her my clients back or torso.

-No real bad points from the bulb holder. If the bulb screw holder is rusted then there is a possibility that the bulb may become tougher to remove or insert.

Here is my client detaching the shade from the lamp.

Here is my client replacing the light bulb via a screw bulb holder.

Conclusion: I conclude that the research shown of my client tackling the process of removing and replacing the bulb is proved easy and sufficient, although there are some problems that I would need to overcome in my final product. For example; the strain of having to reach over the lamp shade to remove and replace the light bulb.

Conclusion: This is a series of images in order of my client removing the lamp shade to gain access to the light bulb in order to remove and replace it.

Clients opinions on the Historical Influences from Venice. Client (consumer) research.

Having selected four images out the snapshots I captured in for the duration of my trip in Venice, Italy.

This particular image my client found very interesting due to the curves and arches on the Piazza Saint Marco. “The marble finish makes this extremely expensive and desirable.” My client was very taken back by the miniscule craftsmanship and great deal of carvings on the building. The features on this building incorporated a series of pale blues, whites and golds.

A closer detailed image of the entrance into the Piazza Saint Marco. My client was interested in the mixture of materials used and was interested in the shapes used.

This is another building from my trip to Venice that my client was intrigued by. My client was predominantly attracted by the curved edges located on the balcony and the archways positioned at the top of the balcony doorway and windows.

Conclusion: Here is a some images shot from my trip to Venice as Primary research. As shown in the images it is of buildings with extreme architectural detail and styles that my client is quite fond of. In addition to this my client is interested in using the ideas of architectural detail (curves and arches) to be included in the final product. My client however is not overly fond of the colour scheme used in most of these buildings.Due to the feedback from my client, I have taken under advisement on what to include and what not to include in the creation of my final product.

In this image is the Rialto bridge, It features a small amount of intricate detail, but a lot of arches and curves carved into the bridge itself. With this my client found it very attractive because of this it gives a little more insight as to what my client may specifically like.

Research Practical investigations 1Photographic evidence of practical investigation

Type of investigation Purpose of investigation What was useful and why? What was not useful and why?

Client views

Laser cutting 3mm Acrylic I am investigating laser cutting in order to find out how to produce an accurate CAD drawing using 2D Design. Furthermore I want to be able to establish what colour line is used for laser cutting (RED). I also wanted to see what a tree design with branches would look like.

I was able to establish strengths and weaknesses in relation to the tree design, for example, some of the branches were far to fragile and would easily snap off. This would be unrealistic if incorporated into a potential solution because the product wouldn’t last 2 minutes.

I think that all of this investigation was extremely useful because I can now see areas that need to be made much wider/thicker E.G. fragile branches made 3mm wide plus.

Not very happy with the colour and choice of material.

Laser cutting 3mm and 6mm MDF

I am investigating laser cutting in order to find out how to produce an accurate CAD drawing using 2D Design. Furthermore I want to be able to establish what colour line is used for laser cutting (RED). I also wanted to see what a tree design with branches would look like. In addition I wanted to see what laser cut MDF would look like.

It was useful because I got an idea of if I wanted to use MDF for any parts of the product, I eventually sprung to an idea of using MDF for most of the final product.

I feel that this investigation was very useful because I can now see areas that need to be made much wider/thicker E.G. fragile branches made 3mm wide plus.

Happy with the choice if material (MDF) more aesthetically pleasing however could include different styles of tree. (leaves etc.)

Embossing aluminium/ enamel paint finish.

I am investigating embossing within aluminium sheeting to test whether or not it is a good finish for my product, following the embossing I added an enamel paint finish to the thin sheet of aluminium to see how It would turn out.

This investigation was useful to me because it assisted me on if it would be a good finish to my product. It also taught me a new technique that I may be able to incorporate into any further products for future clients.

I feel there was nothing negative to say about this investigation in ways of being useful, my only criticism would be that it is not very good for a clean finish on round surfaces.

Don’t like the choice of colour and type of paint is quite bland. Although embossed technique captures the texture.

Routing hardwood and then attaching them to all sides of the MDF panel.

To test if the hardwood frame work would work for stability and aesthetics.

It was very useful because I am going to use this for my final product for my client. However I am going to make some slight adjustments in the process.

This investigation had not faults to it therefore it didn't prove ineffective.

I like the idea of hardwood frame. It is aesthetically pleasing but the colour of the frame would look nicer darker.


Type of investigation Purpose of investigation What was useful and why?

What was not useful and why?

Client views

Same type of hardwood being used for the framework of my clients final product. Test number 1 with high gloss dark Jacobean wood stainer.

To see which 1 out of the 3 wood strainers would prove the nicest for aesthetics.

Because I know that my client wants an in-between light and dark hardwood finish for the frame work so this was helpful because I could then see which wood stainer would be a match for that colour my client is after. In the end this was the colour that my client liked out of the 3.

This was not useless. This particular wood stainer is the most aesthetically pleasing and would be best suited to the final product.

Second wood stainer used but on a different piece of the hardwood.This stainer was called Dark Mahogany.

To see if this wood stainer would look aesthetically pleasing for the hardwood framework.

It was useful because I got to see what colour it would finish as and because my client did like the finishing result. Therefore there is a possibility that it may be included in the final product.

There was nothing useless In this practical investigation.

I felt the finish for this stainer was quite aesthetically pleasing and would like for either this or the one above on the final product.

Third wood stainer used on a separate piece(s) of hardwood. This wood stainer is called Spanish Mahogany.

The purpose of this investigation was to see if it would be a suitable match for my clients needs in the process of the final products hardwood frame finish.

It was useful because me and my client could get a better idea on which of the 3 finishes would look more aesthetically pleasing.

The only negative about this was that it wasn’t the right colour for my client.

I felt that this particular colour was not much different from the original colour.




Client views

soldering a battery operated light circuit with a dark transmitter.

I am investigating soldering and circuitry in order to figure out if a light source is able and functional to be used in the making of my product.

This investigation was useful because it gave me insight as to how a circuit works along with how I can assemble and solder a circuit. It helped me test if my product would have a sustaining light source that can be changed via batteries.

This investigation was thoroughly useful and I therefore have no criticisms as to the usefulness of this investigation.

I like the idea of a battery operated light (s) however I feel it would look better if the wires could be as neat as possible and tucked away.

Engraving into 3mm aluminium. I am investigating engraving into a 3mm thick sheet of aluminium to test whether it would be a good finish to my final product, also to test whether or not it may be good to use that material for my product because that way it may be slightly easier to involve a design within the products body instead of layering a finish on top of the products body

This investigation was useful because it helped me find out if it would be a good finish/material on my product/for my product.

There weren’t many flaws with this investigation, however it wasn’t really what I am wanting to use for my client.

The idea is quite basic (not much is included in it), a more detailed design would have been better

I do not dislike it though.

Annealed copper cut and formed into a risen circle.

This investigation was because I wanted to see if the use of this material and technique proved accurate for the product before I changed the idea. This was going to be use for the sun.

This did prove useful because I thought I would of used it when changing the idea of the product. However I am not going to use this material and technique because it does not fit with the idea of my product.

This investigation was highly useful therefore there was nothing useless about this.

I’m not entirely pleased with this practical investigation, I does however remind me of a potato, I would not want it to be included in the final design product.

Gluing fabric to stage 1 panel to another in order to create a custom hinge between two panels.

This investigation was to test if using this piece of fabric would be able to withstand being used as a hinge between the panels.

This was useful because I knew I definitely wanted to have a hinge between all panels and that I would need to look a bit more in depth with hinging because this did not hold up amazing and was too eye catching and not very aesthetically pleasing.

I wouldn’t say it was a total waste of time, this practical investigation proved useful.

I do not feel this would be a good idea to include in the final product because it would be hard to hide and make less conspicuous. Also it is not as strong as using metal hinges.



What was not useful and why? Client views

Flexi-Play, two sheets glued together then clamped together between a male and female former to create this shape.

To see if using a curved shape and the material would be good to include in my product.

Testing out this investigation was useful because I know that choosing this material and technique would of made a great product. However I have found another technique and material to use for my product so therefore this practical investigation helped me find another way of coming closer to my final product.

There was nothing un-useful about this practical investigation.

The curves are aesthetically pleasing and the smoothness of the wood is appealing. Although on the final product I would not like this to be included.

For this practical investigation I have painted on top of the board that I cut out and glued in between four routed hardwood frames. Mountain shapes were outlined and one of them I painted in to test if it would look good for a finish.

To see if hand painting a design on would be aesthetically pleasing to my client.

It was useful because I know that I will be using hand paints on parts of the final product, however not just fully black

There was nothing useless about this investigation, it was highly useful.

I am happy with paint being used for the final product. The black block colour comes across to plain, and could be improved by adding more detail i.e. by adding texture and different colours.

This practical investigation is me using plexi glue and foil, in this case I have only used small amounts of plexi glue to cover the mountain peaks then then apply an oil slick foil on top to get the effects of snow.

To see if I will be using this on the final product for my client. Following to see how well this investigation went and if it would be a good suit for the final product.

not as useful as the other investigations.

This wasn't very useful because the plexi glue took too long to become tacky for me to apply the foil, it would stick to the glue very well and I ended up with patches. Therefore because of its process and result for that investigation I don't think I will be using this for the final product.

The use of this practical investigation would not be best suited to the final product as it is quite basic and not very appealing.

Cutting out copper mesh in the shape of the mountain and then applying it to one of the cut out mountains that go in the foreground. Then covering the bottom of the mountains with tracing paper in the shape of the next mountain and spray painting over it to get a better colour mixed with texture.

To test if the copper mesh texture mixed well with spray painting for colour to use on the mountains.

It was useful because I know that the copper mesh did not work very well for a texture for the mountains, however the spray painting proved effective because I might possibly use it for the back panel and not on the mountains.

There was nothing useless during this investigation.

With it being a difficult material to work with, I feel I would cause a problem on the final product.


Type of investigation Purpose of investigation What was useful and why? What was not useful and why?

Client views

Vacuum formed green acrylic over laser cut 3mm MDF tree.

To test whether this idea, technique and material would suffice for parts of the product.

It was partly useful because I got to test out further CAD software and ideas that I thought would have been good to use for the product.

I felt this investigation wasn’t as useful as id originally hoped because it didn’t look as aesthetically pleasing along with the work that was needed to cut it out of the acrylic sheet.

I feel as though it is not as aesthetically pleasing as the first practical investigation (3mm acrylic tree. It seems like a lot of work for something that I feel wouldn’t go well in the final product.

Laser cutting into 5mm green acrylic in the form of a thicker template.

This was to test if this it could be used to project light through the gaps or as a design for part of the product.

This was useful because I thought it would be good for a panels for projecting light through the gaps, following this it could have been used as part of the product and still let the light through but maybe in a different form.

I felt this didn’t prove as useful as other practical investigations I have tested. This was because I didn’t think it was a very good design.

I like the idea of light shinning through a gap however a different design would be better.

Routing different designs into hardwood framing.

This was to see which would be a good suit for the final product.

It did prove useful because I liked the thought of using framing round the edges of the final product and also the use of different design was a good way to test the frame work could be improved aesthetically.

There was nothing useless about this. I like the aesthetics of this idea however I would not like it to be included in the final design.

Decoupage on to metal sheet. This investigation was to see if images would fit well onto a material such as metal and if it would be used in the final product.

I felt this investigation was fairly useful because of the use of material and choice of imagery.

I am not going to be using this in the final product due to it being too plain because it is printed images onto a metal sheet.

I like the textural imagery chosen., the vibrant colours. For the final design I don’t feel this would be as aesthetically pleasing, due to the range of images used and bright colours.

Research Practical investigations 6 Photographic evidence of practical investigation



Client views

Engraved tree, followed with gilding flakes and gilding lacquer.

To see if the texture was aesthetically pleasing and the use of colour would have been good to use in the final product but maybe in a different form.

This was useful because I got to learn a new technique and test out my skills within that technique. Also to get a better idea with materials and textures.

There was no flaws with this investigation, it proved useful throughout.

I like this practical investigation because it reminds me of autumn. I like the texture, I also like the idea of this being adapted to a different design. Although the design is very pleasing. I wouldn’t like it to be included in the final design.

I have carried out practical investigations because it gives me and my client insight on which materials would be useful in the creation of the final product, also it gives me chance to explore different techniques that I’m not familiar with for example, annealing. By testing out a range of techniques and processes it has allowed me to become more proficient and skilful which is one of my personal aims. It also shows the development of my skills and ideas because of my client views telling me what she may like to have included in the final product. My client views can help to guide me when I’m deciding which techniques and processes could be used when manufacturing a potential solution.

Problem Analysis (Product development)- lightProblem Potential SolutionHow will I get an original design that appeals to my client? I will research existing lights so that I know what styles are already available.

This will enable me not to duplicate a design.

Materials (availability) My school might not have the type of materials that my client likes. In addition the materials that might be used for the product have to be suitable (properties/characteristics)

• I’m going to talk to the DT technician about what materials are in stock.• If the budget allows, I will order extra materials through school.• If needed I will supply the materials myself.

Environmental/sustainabilityI will have to think about the general issues concerning the environment and think how I can limit the impact.

• Where possible I will try to use materials that are recyclable.• Where possible, I will try to get materials from a renewable source.• I will endeavour to use non-toxic finishes and adhesives.

Finishes (availability) How will I make a product that has a finish, a range of finishes, that will aesthetically enhance the shape and form of the light?

• I’m going to talk to the DT technician about what finishes are available in school.• If the budget allows, I may be able to order a particular finish through school.• I may have to purchase a finish chosen by myself if I require a something that is specialised if

school is not able to produce.

Finishes ( Suitability)How will I find the right finish(es) for my product so that it looks presentable?

I will be carrying out a number of practical investigations with a range of finishes and effects.

Manufacturing methods/processes:What manufacturing methods/processes will be suitable to make the product?Are these methods/processes available in school?

• I will be carrying out a number of practical investigations into various processes such as casting, laser cutting etc.

• I will have to have laser cut components manufactured off site at west Wirral works.

How will I ensure quality standards are achieved throughout manufacture? I will be carrying out QC checks. During each stage of the manufacturing process.

What skills must I acquire in order to be able to manufacture a high quality product? I will be practising new technique/methods through practical investigations for example; I will be learning how to cast pewter.

How is CAD/CAM going to be incorporated into the manufacture of the product. • I will be using 2D design to experiment with different shapes/forms that may be laser cut or to make accurate moulds for casting pewter.

Meeting deadlines.The product must be manufactured by Easter 2016.

I’m going to stick to my time plan whereby I attend extra sessions in DT during school time.

How will I ensure that my product Is safe for my client to use? I will be rigorously testing my product to ensure that the client cannot be injured in anyway.

Conclusion: The key points of this problem analysis are that the product must have an original design because my client wouldn’t want something already created along with making sure that the product is environmentally friendly and that all resources are sustainable. The last two key points are to ensure the product is safe for my client to use and to also meet the deadlines for this course. The information that will help me will come from my client, to ensure the design is original and appeals to my clients liking. Also using the knowledge from the internet and my teacher I used that information/knowledge to choose the correct resources to create my clients product ensuring the safety of environmental issues and chemical/toxic issue, furthermore because of the knowledge my teacher gave me I knew how to ensure the manufacture of the product is made sufficiently. The reason I have chosen these key points is because they enable me to get a more accurate reading on the creation of my clients product with ensuring it

Problem Analysis (needs of the client)

Problem Potential SolutionHow will I identify the needs of my client? • I will speak to my client and establish her likes/dislikes, hobbies/interests and so

on. I will then use this information to build a detailed client profile.How will I ensure that the potential product is ergonomically compatible with my client?

• I will ask my client to perform ergonomic tasks with regard to her existing lighting e.g. structuring it on/off, taking the lamp shade off etc.

How will I be able to satisfy my client’s specific tastes? • I will find out the likes and dislikes of my clients views towards colour schemes and shapes (forms etc) and make a clear choice on what would be best for my client with this product.

How will I be able to make sure the product is not harmful or unsecure? • I will ensure QCC (Quality Control Checks) are carried out throughout the process of the final product to make sure that it is not harmful for the user(s) and that it is secure and will not break or case damage to any other object or surrounding.

How will I ensure the product produces a sufficient amount of light that meets the standard of light my client requires?

• I will do research into lighting and electrics to see what types of lights there are and if any of them can be miniaturised to fit the product but also to be aesthetically pleasing and not untidy. Also ensuring that they are safe and easily accessible and not dangerous.

Conclusion: The key points here are how will I identify the needs of my client, how will I be able to make sure the product is not harmful or unsecure following the satisfactory of my clients specific tastes. I have chosen these key points because they are the most important in ensuring my client is 100% happy with the outcome of the product. These key points will help with the design of my product because it will also be personal to the client because it will meet the expectations of her needs and tastes.

Analysis of research tableTopic What is useful and why? What is not useful and why? Comment

Product Analysis After analysing a number of primary lights, I found out about the different materials, process, finishes, and techniques that have been used to manufacture each product. Its also enabled me to establish what colours are in trend and what styles are also currently popular. That styles that I have researched are quite minimalistic with the lack of ornamentation. A lot of the lamps are very similar e.g.. A fabric light shade with a separate base. Finally my research has enabled me to determine size and proportion with regard to each product that I have analysed.

All of the lights that I have researched are quite basic and lack creativity. The products don’t provide me with any inspiration because they're so basic and lack individuality therefore I will not be able to draw any inspiration from the product analysis that I have carried out. I will have to look or another source that will fire my imagination and help me to think of creative potential designs.

Although it gives me an idea of how these products have been mass produced, It doesn’t give me any inspiration for being innovative and creative either my own designs.

Client profile 1 Interviewing my client has enabled me to establish her specific needs for example; she likes metallic pinks and purples and some shades of green. In addition her favourite themes are flowers, outdoor scenery such as trees and mountains. Furthermore, she enjoys organic forms that look very natural. Finally I have been able to determine where my client would like a potential light to go in her house. In addition my client would prefer the living room because it’s the room that is used the most by her and her family and also there was an area that needed something to make it more interesting because it look bare and sparse. Finally she wants a product that is going to be bespoke and make a statement when friends and family are in that room.

All of the information, apart from my clients interests such as having a meal and walking the dog, have been useful and will help me to determine her exact needs.

From speaking to my client I have established that the theme must be based on organic natural forms such as trees and mountains. In addition the colour scheme should contain some metallic such as pinks, purples and shades of green. Finally she wants the product to be bespoke so that when friends and family walk in the room it becomes a talking piece. Furthermore she isn't concerned with the product having the light being bright but prefers low level lighting that would create ambience.

Client profile 2 This information is extremely important because I have been able to establish what my client really likes in terms of aesthetics for example her favourite piece of artwork features 3 individual panels which collectively form a picture. One of the things she particularly likes is natural forms such as mountains. This is because she finds such images relaxing and peaceful after a hard days work. In addition I was able to establish what sort of colours and tones that my client particularly favours such as a range of green to grey tones.

I have found that carrying out another detailed analysis has been really useful because I have a firm idea of what my client likes and what her personal tastes are. I will therefore be in a very good position to be able to design a product that suits her personality.

It is my intention to incorporate organic images/forms such as mountains. The reason that I am going to try to incorporate mountains is because my client has specifically mentioned that mountain themes are relaxing and peaceful. In addition she has also stated in client profile 1 that she likes natural forms such as mountains therefore it is obvious that my client favours mountain scenery.

Mood board and analysis

The mood board enables me to show my client a range of images based on her preferred themes e.g. natural forms. I've incorporated her favourite colour schemes, pinks, purples and greens in order to inspire my clients thinking. I’ve it particularly useful when trying to discuss shape and form with my client because I can point to a range of different images and get a immediate feedback. In addition its given me inspiration particularly deciduous trees during winter time. Furthermore my client likes deciduous trees because she can see more detail with regard to branches, formation of twigs and the spaces in-between.

One of the images (a bundle of towels) was meant to show my client a possible colour option rather than shape and form. The mood board is lacking in images of mountain scenery. Sin she cannot draw inspiration from this mood board and I cannot indicate potential images that may inspire her decision making.

my mood board has given me a starting point when discussing possibilities with my client. I was able to show her a range of organic images that helped her to make decisions for example what types of trees she particularly liked and colour combinations. However I was not able to establish what type of mountain scenery she particularly favours and why. If time allows I will add images of mountains onto the mood board in order to present my client with further possibilities.

Anthropometrics the most important information are the hand measurements and pincer grip because I will be able to design the product to suit my client’s specific anthropometrical measurements. This will allow me to incorporate features that make it easy for the client to use for example; positioning of switches.

All of the information to do with anthropometrics has proved very useful because I will be able to make informed decisions when planning, designing an manufacturing a bespoke light.

It is my intention to use the measurements that I have acquired from my client to help me to establish suitable positions for light switches (if appropriate). In addition pincer grip will be useful with regard to any detachable components such as power supplies, decorative interchangeable pieces and so on.

Ergonomics This research has proved useful because I was able to see what range of movements my client could perform with regard to changing light bulbs, switching on a rocker switch and so on. I was able to establish that my client found it easy to disassemble a light shade but struggled to replace the bulb. This was because she had to stretch her arm across the top of the shade in order to reach the fitting. She found it slightly uncomfortable overstretching and found herself straining to replace the blub.

All of the information was useful because I was able to determine what actions my client could perform comfortably. I will be able to bare this in mind when I am planning, designing and manufacturing a potential product.

After analysing this information I will be designing and manufacturing a product that is easy to use and does not require my client to strain in any way. Furthermore I will ensure that detachable components are easy to disassemble and reassemble without causing injury. In addition any switches and buttons must be situated so that the client has immediate and easy access. This will reduce the need for my client to overstretch herself when performing manual operations such as turning the light on and off.

Analysis of Research Table 2Topic What is useful and why? What is not useful and why? Comment

Historical Influences From my visit to Venice I took a range of photographs of historical architecture that look particularly interesting. I showed the images to my client in order to gain insight from speaking to her about construction details such as spires and balconies, colour schemes and so on. These images have proved very useful because I was able to determine that my client was intrigued by curved forms especially featured on balconies archways and above door entrances. Furthermore curves are very organic as opposed to harsh rectangular shapes and lines.

Although this information has been in the main very useful all the forms are man made and are up to a point contrived. There are no organic features such as leaf shapes, flowers, mountain scenery which my client particularly likes. Therefore most of these images do not inspire my client in the same way that images of natural forms do. This is because she does not find them very relaxing to look at.

After analysing the historical images it is my intention not to be influenced by architectural features such as archways, balconies and brick details. This is purely because my client does not find the images peaceful or relaxing and would find herself over stimulated by thinking to deeply about the construction and details such as murals that she can see.

Practical Investigations 1,2,3,4,5,6

After carrying out a range of practical investigations I had found the most useful ones to be Embossing aluminium sheet metal, constructing a hardwood frame, different painting techniques I.E hand painting, spray painting. In addition laser cutting was an interesting process because I was able to experiment with different forms. Furthermore I found the practical investigation into creating a mood light circuit particularly valuable because I was able to see what kind of light the circuit omitted.

The practical investigations that I have found not useful were forming flexi-ply over forms in order to create curved shapes. This is because I wasn’t able to achieve tight and precise bends and curves. In addition vacuum forming very crude and that it looked amateurish for example poor definition with regard to branches and texture. Furthermore my investigation into decoupage proved uneventful because the images looked far to random and uninspiring as well as flat. Finally my investigation into engraving onto 3mm aluminium wasn’t to mine and my client’s taste because it looked bland and there wasn’t enough detail. Finally my investigation into plexi-glue and foil proved rather disappointing because I was expecting as better finish. I found the glue difficult to control and manipulate into fine detail.

After carrying out 20 different practical investigations and getting direct client feedback I have established which processes and techniques are going to inspire my designs. The processes and techniques that I intend to investigate further are laser cutting, various types of painting techniques as well as working with metal such as copper. The reason I have selected a few practical investigations is because my client has very specific needs such as mountain scenery. I think I will have to incorporate 3 dimensional mountain scenery into a potential product. Laser cutting might prove useful especially contouring.

Conclusion- after carrying out all of these investigations I have been able to establish which process and techniques are going to inspire and influence my designs. The most valuable investigations, from what I can see, are laser cutting, soldering circuits and working with metal. This is because I want to use techniques and processes that enable me to create a sculptural bespoke product that will have illumination.

Specification-ProductSpecification

Explanation

1. The lighting product will be capable of easy removal for the light and any other possible features that require physical movement or tension.

The lighting product will be designed to ensure the user is able to remove the light source, following any other components that may need to be removed in the process of removing and replacing the light source or a lamp circuit.

2. The product will disperse enough light to give the room Illumination of the expected amount. It will have to be user friendly meaning not too hard for the user to turn on and off.

The product will have a lighting source of ultra bright LED lights that will generate a substantial amount of light in whichever room/area it is supplied in.

3. The lighting product will be designed so that it is portable and can be utilised in any suitable area. The lighting product is to be designed well for weight so the product is not difficult for the user to transport. It will have to be designed in a sufficient way for the user to mobilise the product without strain or struggle, not a ridiculous size and well thought out in ways of possible deconstruction.

4. The light product will be based on an organic theme. My client favours organic themes such as trees, mountains and leaves.

5. The outer body of the product will be easy to clean, by simply using a wet wipe/cloth. The product will be easy to clean because the surface shall have a layer of lacquer covering it which will then make it easier to wipe clean. In addition, the material that the product has been manufactured by will allow the wipe/cloth to remove any dirt or grease with ease.

6. The product will be original. The product will be manufactured from a series of inspirational ideas to eventually arrive at the final idea. This will mean it wont be copied from an idea already created.

7. The product will have a specific colour scheme. My clients product will have a chosen colour scheme specific to her interests and preferred colours.

8. The product will be manufactured by using a range of processes for example, casting pewter, laser cutting, flexi-ply and formers etc.

Using a wider range of processes may enhance aesthetics of the product as well as making it look more interesting for the client.

9. The product will be manufactured for my mum (client) The product I am creating will be manufactured for my client (Mum)

10. The product will be manufactured to a high standard by carrying out QC checks at all stages. The product will have multiple QC checks after the manufacturing process is complete.

11. The product will be used in the living room. Because of my client redecorating her living room, my product will be manufactured to correspond with the outcome of her new decorated living room.

12. The product will be safe during use and miss-use. During the use of this product I will want it to be safe at all costs. In addition to this even during miss-use I will also want my product to be safe so the client(s) do not injure themselves while the product is not in use.

13. The product will be made from sustainable materials as far possible for example, that has came from a renewable source.

Materials that need to be renewable and environmentally friendly need to be planned and thoroughly thought over before applying materials to the product itself.

14. The product will interoperate components that have been manufactured by using CAM. Components that need to be cast must have accurately manufactured moulds-preferred method laser.

Conclusion: I conclude that key points in my product specification are the most important because they are the biggest factors to make sure my clients product is fully accurate with what she wants and to ensure it is safe to use and will cause no harm or effects to the user. These specific key points I have chosen are having a light easy to remove and replace if necessary but also to switch on and off. Following this ensuring the product will be safe during miss-use and when being used (no sharp edges or points) furthermore I intend to follow the design of the product being easily portable and suitable in any area. These points will be crucial in the design and development for the final product for my client.

Specification- Client

Specification ExplanationThe client would like the product to include wood and metal. This is because my client finds wood grain finishes aesthetically pleasing, also the

metal can have an applied finish which my client likes the thought of.My client’s favourite theme is floral. She finds floral patterns very tasteful due to the feminine design that appeals to her.

In addition, flowers are natural forms and organic which my client likes.Natural and organic forms such as leaves, trees and mountains.

During and interview with my client she said that she really liked natural forms such as mountains. Natural forms remind her of going for long leisurely walks in the countryside, one of her favourite pass times.

Relaxing and peaceful imagery. My client expressed a keen interest in imagery that she finds particularly relaxing such as natural forms. This is because she has a stressful job and works very long hours and often doesn’t get home until 9.00pm. Furthermore, she wants to be able to just sit down and unwind after a long day.

Shades of green and metallic pinks and purples. During and interview with my client she said that her favourite colours were metallic pinks and purples and shades of green because they look very natural and remind her of the outdoors (flowers, trees and grass). Pink and purple are also her favourite girly colours.

Separate panels. My client already possess artwork that is split into three sections and she has expressed a keen interest with regard to having a product that looks more unique. She likes the idea of having more versatility and being able to rearrange components in order to suit her mood.

I’ve based my client specification directly on an interview with my client prior to writing a detailed client profile. This info will help me make informed decisions when I’m planning/designing/developing and making a potential product.

Ideas against client specificationSpecification Idea 1 Idea 2 Idea 3 Idea 4 Idea 5 Idea 6 Idea 7 Idea 8 Idea 9 Idea 10

The client would like the product to include wood and metal. 3 2 3 3 2 2 3 3 3 3

My client’s favourite theme is floral. 0 1 3 3 2 0 2 0 3 0

Natural and organic forms such as leaves, trees and mountains. 2 1 3 3 2 1 1 2 3 3

Relaxing and peaceful imagery. 2 2 1 3 1 1 2 2 2 3

Shades of green and metallic pinks and purples. 3 0 2 3 1 1 1 3 3 3

Separate panels. 0 0 0 0 0 0 0 0 0 3

Totals 10 6 12 15 8 5 9 10 13 15

Conclusion: After evaluating all of my ideas I have found out that Idea 10 is the most suitable because it matches the client specifications the most, therefore I am going to develop this idea into a final solution. I will be involving my client throughout the development and planning stages so that her specific needs are met.

Ideas against Product specificationSpecification Idea 1 Idea 2 Idea 3 Idea 4 Idea 5 Idea 6 Idea 7 Idea 8 Idea 9 Idea 10


3 2 3 3 2 3 3 3 1 3


3 1 3 3 3 3 3 3 3 3

3. The lighting product will be designed so that it is portable and can be utilised in any suitable area.

3 3 3 3 3 3 3 3 2 3

4. The light product will be based on an organic theme. 3 3 3 3 3 3 3 3 3 3

5. The outer body of the product will be easy to clean, by simply using a wet wipe/cloth.

3 3 1 2 3 3 2 3 3 3

6. The product will be original. 3 3 3 3 3 3 3 3 3 3

7. The product will have a specific colour scheme. 3 3 3 3 3 3 3 3 3 3


3 1 3 3 3 3 3 3 3 3

9. The product will be manufactured for my mum (client) 3 3 3 3 3 3 3 3 3 3

10. The product will be manufactured to a high standard by carrying out QC checks at all stages.

3 3 3 3 3 3 3 3 3 3

11. The product will be used in the living room. 3 3 3 3 3 3 3 3 3 3

12. The product will be safe during use and miss-use. 3 3 3 3 3 3 3 3 3 3


3 3 3 3 3 3 3 3 3 3

14. The product will interoperate components that have been manufactured by using CAM.

3 3 3 3 0 0 0 0 3 3

Total 42 40 41 40 37 39 37 39 39 42

Conclusion: After evaluating all of my ideas I have found out that Idea 10 is the most suitable because it matches the client specification the most, therefore I am going to develop this idea into a final solution. I will be involving my client throughout the development and planning stages so tat her specific needs are met.

Development modellingThis was the first model I has created using 2D design at west Wirral works then processing it in a laser cutter, following with constructing it using PVA (Polyvinyl Acetate). The purpose of this model was to see if I could create the start of a tree trunk by layering up this laser cut design, the technique to this was contouring on 2D design so I wouldn’t have to create a new page for designing the same one but on a smaller scale. This didn’t prove as sufficient for a lighting product.

This is where the initial ideas sheet helped me further to producing my final product. I had came up with a tree design that would have either engraved or laser cut grooves throughout the trunk and branches of the tree that would had light shining through them in order to give the area of choice light with a pattern. This design was created from one of the ideas on my initial ideas sheets, I developed it into this panel that could possibly be glued with PVA or Bostic glue onto a backing made up or either further 3mm acrylic off cuts or an MDF box backing made up of offcuts. This would then allow a simple battery powered LED light to shine through the cut out design in green acrylic.

This model was created using a cylindrical prism with the same template cut out of aluminium though for an easier bend to fit the shape of the prism. Holes were also drilled into the prism, this is so the LED light can produce light through the model to illuminate the area of the room. The LED light that I had planned on using for this design was a colour changing LED that was attached to a circuit board and create mood lighting for the user.

Similar to the previous model the only difference with this one is that there aren’t as many holes drilled into it, also it has been cut in half and 1 side has been glued with PVA and black fabric in order to create a custom hinge so the light can be opened and easily accessed if necessary. This design could be further developed by adding a bottom and top circle cover, following a stainless steal bass and stem to add height and further aesthetics. The fabric hinge could also be changed in for small metal hinges with tasteful aesthetical designs. The product could be made from a different type of material, like wood, or metal (annealed for texture).

This model was constructed from MDF and green acrylic of 3mm thickness and included the same template design from the one stated above. The 2 MDF panels were positioned differently than the acrylic panel in the middle. Following this a light could also of been added behind this design in order to shine a multiple pattern through each cut out design. Like the model design above states, a box backing could be added to each one of these template designs and a battery powered LED could be added inside to illuminate the area of the users choice. This model if developed further into a final product could be completely made up of an acrylic case with a different design added, or a complete MDF box with a different design based around a more natural design, including trees, moons/sun in the sky, or mountains, even an ocean design. That would depend on the clients tastes.

Conclusion: I conclude that the development of modelling has proved helpful due to improving my designs and giving me more inspiration for developing each design further into a final product. My client was very pleased to see how far I have come to making the final product.

Development Modelling 2

Conclusion: After producing these models I quite liked the idea of the picture framework but producing them by using Mahogany, also the use of thick materials such as MDF to then hand craft into a 3D effect for a more interesting/unique design.

I have created this model as a step further to creating a light with panels attached by custom fabric hinges, following detail in a softwood (Pine) frame. These details included rough cut outs of cardboard mountains that were spray painted to get an idea of if spray paint would be suitable for the final design on the product.In this model I have decided to include a series of mountains in a continuous landscape design, this also enabled me to possibly include different materials and textures to each panel that would make the final product more interesting and give it more wow factor to the user. I feel this design has potential as a possible sculptural piece of art (ornamental piece) but not as a light due to the thickness of the design, this I have then developed this into a further idea/design by using the panel design idea including the continuous mountain theme following detail with different materials and textures such textured spray paints for the mountains, and embossed aluminium for further mountain details. In addition the use of tree(s) has been very influential due to it meeting further tastes of my client and would be a good break away point from the mountains. The good points about this design are that it meets my clients tastes with natural forms, different materials and textures being used, also the use of panel pieces for each section of this model has been inspired by one of my client’s art pieces that she has hung on her living room wall. That specific piece I feel has been the break through with this design to point me in the right direction of the final product.One of the bad points for this model is that I feel I would of struggled to make a light out of this unless I modified it to have a thicker wood picture frame around each side of the model enough so the power supply and light would be able to fit in. another bad point is that there was not much included in the rest of the space such as a sky with either a sun theme like sun rays shining that could then have a light behind it to emphasize the sun shining in the sky, or a moon and stars with a dark sky and the light being placed behind it to illuminate a star/moon pattern when the light is switched on.This model does meet a fair few of the points from my client specification, e.g. natural/organic forms such as trees and mountains, wood, separate panels and relaxing imagery being used. Also easily transportable as well due to the fabric hinges they can fold over each other and because of the scale of the model matched with the weight it means it is portable with no cause of stress or strain.

For this model I have tried using a different approach instead of using cardboard glued between softwood (Pine) framework, all I have done is used cardboard as a rough back panel with a cut out 3mm MDF mountain that links all together but is constructed of a background and foreground mountain scenery in addition with a laser cut 3mm MDF tree to meet another one of the points my client specification. The model is constructed using a separate panel layout with parcel tape as hinges just to hold it together but still gives it an easy collapsible feature that makes it easily transportable mixed with the scale of the model and the materials used without causing the user any strain. However, I feel this model would not be very good to develop further into a final design due the to lack of interest and used of materials and textures that would be able to be applied to it. I would suggest that hardwood (Mahogany or balsa) would be a good choice to use for the back panels which would give it an aesthetic appeal along with a more sturdier structure. In addition to this thicker MDF would be a good use for the mountains and tree because it could then be sanded down to create a further 3D effect and also could either be hand crafted or engraved with a design following this I would enlarge the scale of this design/model in order to add more detail In it e.g. the sky to become more desirable by the client. For the power supply I would suggest a thin backing on the hardwood panels in order to fit a small battery pack attached to LED strips which would then shine through a design that could be set on either a daytime or night time sky theme that would be laser cut above the mountains to not only fill extra space by add further detail and create more opportunities for adding textures such as a highly polished annealed sun for the daytime theme or a highly polished cast pewter moon. This model does meet a couple of points with my client and product specification such as; separate panels, natural/organic forms e.g. trees and mountains.

Development Modelling 3

Conclusion: one of the key factors that I have found out is that size and proportion is extremely important for example, I need to get the light the right size so it fits into the available space neatly.

This model is one of two this being the larger and wider scaled model, this was to test whether the final product would be suitable by using this sized scale. this was good because it gave me a more accurate reading when testing it in the correct environment that the final product is being designed for (living room corner by the corner of the couch).The only bad point for this model is that my client found it too tall/high for the chosen assigned place. This model only follows one of the points met by my client’s specification, this is that the product includes a separate panels design.

This is the model being tested in the assigned environment.

Due to the issues with height the first model this is why I had more than one model to ensure that I could test a different size/scale quickly instead of going back and creating another one that was a different size.

This is the model being tested in the assigned environment.

This is the second model out of the two and is scaled smaller in height and thinner in width. This was to test if this would be a more appropriate size if the first one did not work out, as was the case this model proved that this scale would not suffice due to the selected environment the final product would be created for requires a more larger scale. There was only one good point and that being I now know what scale I will be creating the product.

This is a one of the prototype models that I have created towards the final design. It consists of a routed hardwood (Mahogany) framework that I have varnished with a dark Mahogany wood stainer in order to further test one of my practical investigations because this was one of the 3 stainers that my client liked. The good points for this model was that is gave me the inspiration to use a hardwood frame round the top, bottom and sides of the panel. There were no bad points to this development model.In addition to this I would improve this modelled design by including a backing where the power supply would go (behind the panel but with a design of the clients choice laser cut towards the top to ensure that it was not in the way of any other potential design located towards the bottom of the panel. Further more this modelling design only meets one of the points in the my client specification (separate panels).

This is the second prototype that I developed further including a back and foreground mountain design that was then painted using a solid black acrylic coat and then a white acrylic paint and dry brush technique to create a sense of snow and further detail within the mountains for a better idea of how if the use of mountains would be a good choice to include for the final design. In addition to this I also used a high gloss dark Jacobean wood stainer that was simply lighter that the dark mahogany wood stainer. This gave the hardwood framework a more classy aesthetic appeal to my client due to it capturing the grain of the wood more. There were no bad points to this developed model. I would not included any improvements due to this being the last model towards the final product. Furthermore this model meets more points from my client specification such as natural/organic forms, separate panels and textural detail being included.

-If I were to improve these 2 models I would have created another model that was the correct scale of the assigned environment I was designing the final product for. To do this I would of measured the environment and collected feedback from my client and asked her to take measurements herself in order to gather a more accurate result.

Development through CAD

What is the drawing of

What is good about the drawing/why?

What is bad aboutthe drawing/ why?

How could it be developed further?

Clients views/feedback

Conclusion

The drawing is a ray of sunshine coming down from the far right hand panel.

One of the good points is that it meets one of the clients points with including natural and organic forms.

It is a tricky design and to be process on the laser cutter it needs to ensure that it isn’t cut right through from right to left on the laser cutter.

I could develop this design further by including further sun detail and possible animals in the sky like seagulls or other bird like animals or even clouds.

“I do like the use of natural sunny skies. However, the use of a night time theme would suit the product more.”

I conclude that even though my client is positive about the design and it meets her tastes, it wouldn’t prove as much of a pleasing back to the final product.





Clients views/feedback Conclusion

The drawing is of a butterfly that has been vectorised.

Because it meets one of the points for my client(floral theme).

I feel this would not be very good to use in the final product due to the random nature of the leaves and butterfly.

I don’t feel this design could be developed much further apart from the different shapes of leaves.

“I don’t feel this would be very aesthetically pleasing due to the numerous types of leaves, I don’t think that this would be a very good idea to include this in the final design.”

I conclude that this drawing hasn’t proved as useful as the above due to the displeasing aesthetics.






This drawing is of a single Birch leaf with intricate detail included on the inner part of the leaf.

This drawing explores different details using CAD 2 and also meets a couple of my client’s points such as natural/organic forms and slight floral themes.

This design was quite basic in in terms of types of leaf.

I could use a different type of leaf, one that includes a lot more detail, also I could add multiple leaves together in order to make a bunch that may give it further aesthetical positivity from my client.

“I think this drawing is quite interesting due to the amount of detail included on the inner parts of the Birch leaf. However I wouldn’t like this drawing or any other leaf drawing to be included in the final design.”

I conclude that this analysis has been helpful because it has reveal that my client would not like this drawing/design to be included in the final design.

Conclusion: After developing through these designs using CAD I have decided that the like of leaves and a daytime theme will not be included in the final design and will therefore be focusing on night time and mountain designs with possible trees included.

2D Design CAD For Product

What is the drawing of What is good about the drawing/why?




This drawing is of a series of mountains that I had collected of images and then vectorised them all.

This is good because it meets my clients points of organic features such as mountains.

In my opinion there are no bad points.

I feel this could be developed further by adding some of the most unique mountains together and adjusting them.

“I really like the idea of mountains being used however I think it would be better if the mountains were a continuous design fitting together in size etc.”

I conclude that this will be included in the final design including the suggested improvements by my client to further meet her tastes.





This drawing is of a tree that I have developed into a series of trees (all different sizes and shapes) that flows in a continuous pattern from panel to panel.

The end result because of the aesthetic appeal to the style and size along with meeting points from my client such as including natural/organic features.

There are no bad points about the drawing.

The drawing could be developed further by including more trees in a smaller scale to possibly create an even more 3D distance effect.

“I really like this drawing because it includes trees that are very appealing. I think this would be a very good design to include in the final product.”

I conclude that this development piece has been very successful with hitting my high standards and my client’s tastes towards the final design.





This drawing is of a star that I have then developed further into a series of stars all in different scales.

This drawing is good because it gives the final design a more unique perspective for the client.

There are no bad points about the drawing.

I feel that there could be more stars in different shapes and sizes in order to give the light that will be place behind it a little more room to shine through.

“I feel that this could be a very interesting touch to the final design due to this being an idea I hadn’t considered.”

I conclude that this design has again proven very successful for the client which enables me to bulk out the final design further.

Conclusion: after looking at the previous CAD designs and discussing with my client I have decided to look at mountains, trees and a night time star themed sky for the final design. This my client is very happy with and would want to be included in the final design.

CAD Development

All laser cut components and moulds were processed at a CAD/CAM centre, West Wirral Works. When work was ready for processing it was emailed to the technician with full instructions i.e. which material was to be cut. Where applicable, students would nest their work making it faster to process and more cost effective.

This is the final design I produced on 2D Design.

This is a panel extension along with a very back panel that I designed in order for the battery pack to fit and for a set of LED strips to be presented in.

These are the background mountains that I designed for the final product.

Here is a closer look at the design.

Conclusion: After carrying out a series of investigations with CAD and discussing with my client I have arrived at this design which will be incorporating mountains, trees, stars, contouring and moulds for pewter. Due to the amount of components included in this design, I will have to adapt the manufacture of the product to fit the client’s needs.

This design is to act as feet for the product to keep it standing still. Once the package arrived full with all the materials I needed to create the product, I decided to modify this mould in order to create a pewter moon mould because this mould was too big and would of made the product look displeasing.

This is the same design as the previous mountain panels, the only difference is that this is a contoured version meaning it is slightly small in terms of mountains which enables me to then sand the mountains down for a 3D effect.

This design is the foreground mountains that are smaller in terms of size and also completely different in arrangement and shape.

This design is the middle panel which will act as a template for the light to shine through but also reflect a pattern on the whichever surface it is placed against.

This is what the mould looked after I modify it to fit the product.

Quality Control Checks (QC)

Checking for 90 degree angleAnd straight horizontal Spray and Paint test

Drill test Neat adhesive appliance

I have carried out this QC check to ensure that the inner panel pieces for each separate casing was at a perfect 90 degree angle on each corner. In addition to this I also checked the vertical width of each inner panel siding. This ensured 100% accuracy by giving me a perfect result for sanding down the inner panel pieces along with making sure everything was to an accurate line with no unnecessary lumps and bumps.

This QC check ensured me that the textural spray paints I was planning on using did exactly what they said they were going to do, therefore I manufactured a spray test on one of the excess mountain pieces before carrying it through to the final product. This test ensured textural and visual pleasing for when carrying out to the final product. In addition I also carried out a QC for testing different shades of grey, black and whites before applying the dry brush technique with the different paint shades on the embossed aluminium. This was also to ensure I achieved the correct colour scheme as I had a specific one set out in my mind.Client Views: “I feel these tests were very useful and a good use of excess materials, it has helped achieve an amazing final product due to care to detail.”

This QC check was to ensure that the drill head I had chosen was the correct drill head I needed to ensure that once drilling the holes, the screws I was going to use matched the size of the hole. In addition to this, this QC check proved very effective because the screw fit perfect in the hole which enabled me to achieve 100% accuracy with the final result on the final product.

This QC check was to ensure that all adhesives applied were neatly done with no excess that may have squeezed out of the gaps that were being tightened together by hand/G-clamps. I used a paper towel in order to do this. This was to ensure all components that were glued together in order to achieve a clean, smooth aesthetical product but also to ensure that it did not become a further hassle with any parts not being able to be stuck together because of excess PVA that had dried.

Scribing Front TreePanels

Cast Pewter Butterfly

Measuring Velcro strip next

To battery pack

Checking Battery pack

Fits in the Back extension

Panel beforeAnd after.

This QC check is me using the scriber instead of a pencil to mark out the excess MDF sides where I then sanded them down in order to gain a fully accurate fitting with the front tree panels.

This QC check was to ensure that I had the right sized hole punchers and technique to then use on the final cast pewter moon for textural and aesthetic effect. I carried this QC out to ensure that the accuracy with the hole puncher was effective and to high standard.

This QC check was to ensure that before applying the adhesive Velcro on to the battery pack, I had the correct measurement. This was also to ensure that the Velcro strip did not cover the On/Off switch located at the top of the battery pack on one side.

This QC check was a before and after shot, the before shot was checking how many back panel extensions I needed for the battery pack to then fit comfortably without being too slim or too thick when attached to the middle laser cut star panel. The after shot was once the product had come together further and I was working on the electrics I tested to see if the battery pack still fit comfortably in the assigned place.

Conclusion: The reason I have carried out all of the QC checks was to ensure that I met all of the points in my client and product specification to the max. Secondly It was to ensure that I achieved high accuracy when manufacturing the product so that it looked professional, worked properly and pleased the client fully.

Quality Control Check(QC) and Templates

Pewter moonTemplate for Curved filing

2 tracing paper templates that were then outlined onto paper

for aluminium mountains

Paper mountaintemplates

Mountain outlinesLeft in aluminium Sheet.

This template was tracing paper that I marked out a circle on using a compass from the measurements taken of the diameter of the cast pewter moon once wet and dry sanded.

This template was out of tracing paper that I marked out the correct mountain shapes on that I then marked onto paper for a more sturdier surface.

These templates are of the paper mountains that I marked out using the previous mountain tracing paper. This was for a sturdier template to take further to outlining the mountains shapes onto aluminium.

These template cut outs are of the mountain outlines in the aluminium sheets that were left for the final product.

Series ofMountains

Cut usingcardboard

Copper circleTemplate for

Annealed Copper sun

5mm green acrylic +Development model

Tracing paper mountain cut into 4 sections=3mm MDF mountain

These cut out cardboard mountain pieces were to gather further templates/mountain shaped ideas for further modelling/development pieces.

Template/outline was constructed from copper and using a double pointed sea compass to mark out a perfect circle that was then going to be used for the annealed copper sun but shortly after I then modified the design of the product to fit a night time theme so therefore I used cast pewter instead.

This template is made from 5mm green acrylic which I then used traced the inside design onto some aluminium which I then turned into a laminate for one of my development models.

This template was out of tracing paper of a mountain design that I thought of in my head. Following this I decided to cut it into 4 sections to then be traced onto a sheet of MDF. In addition to this the 4 sections were to meet my clients tastes of incorporating separate panels as a future model/design.

Conclusion: These are the templates that I created/used in the modelling/developing of a series of different models and also designs that went into the final design. I have done this in order to achieve a high level of accuracy. This worked very well because it ensured it would not mess up and mean for me to start again.

when the start to my client’s product first arrived (laser cut contoured panels) I had arranged them in order of the biggest to the smallest. This gave me a better idea on what I was dealing with and how to go about further manufacturing the product.

This is where I then started to glue each panels to each other using PVA (Polyvinyl Acetate) in order to get a strong stick between each of the panels. Every panels was glued together in correct order (Biggest to smallest).

Next I used G-clamps and weights to hold the glued panels together tightly but not enough to break or damage the panels in the process. Wait till dried (24 hours for best solid stick).

Once all panels are dried I chose a heavy duty file with thick, sharp teeth from the tool cabinet and I filed each mountain peak until every part of the mountains on all panels were rounded off to create a 3D effect along with a round file to get further more intricate detail in the mountains.

Visual QC check to ensure that none of the arriving materials were damaged in the process of laser cutting or transportation.

Visual and Physical QC check to ensure that the panels where glued in order and properly.

Visual QC check to ensure that the G-clamps were in place properly and the weights were distributed correctly.

Visual and Physical QC checks to ensure that the newly curved mountains are smooth with no rough areas along with ensuring that it to high quality standard.

Care was taken when taking the materials out of the box it arrived in, piece by piece was carefully handle when coming out of the box.

Clear work surface to ensure that the materials were not damaged or marked in the process.

Heavy duty boots/shoes worn to ensure that feet were protected, however further precautions were taken (feet kept out falling distance from possible falling G-clamps and weights).

Care was taken when filing the mountains to try and avoid any injuries such as little cuts or grazes from catching my skin in between the file and wood.

After filing the mountains down I started filing the inside of the panels to get rid of the laser burns left from the laser cutter and to smoothen them down.

This was the one of 4 finished panels. I used smooth sand paper in order to create a smoother finish to then apply primer to it later on the in the manufacturing process.

This was the very back panels which have laser cut stars towards the top where the sky will be also located.

In addition to the laser cut stars on the back panel I felt were not enough therefore I added some drilled holes of different sizes, and in a random order that still kept the stylish look of the back panels.

Visual and Physical QC checks to ensure that the insides of the panels have been filed down correctly with no more laser burns left.

Visual QC check in order to ensure that high quality of detail has been included along with the aesthetics of the panel(s) have met the best standards.

Visual QC check to ensure none of the materials are damaged or contain defects.

Visual QC check to ensure that the holes drilled are no to random and displeasing. Following this ensuring that the holes have been drilled properly.

The same with the previous health and safety check. Ensure that care is taken when filing because of possible cuts or grazes that could occur when using a heavy duty file.

There no health and safety issues. There are no health and safety issues. Wear goggles and apron along with keeping all loose clothing tightly tucked away, also make sure that drill guard is in place and locked, also clamp down the piece being drilled.

Manufacturing Log 1

Manufacturing Log 2

Here is each star back panel and mountain panels in segments (not fully glued together) to get a further idea of how far along I was. As shown the inside wall of each panel piece needed filing and sanding down.

This is one of the panel pieces not fully glued with a USB powered colour changing LED wired through the unglued gap between the mountains and located behind the tree panel in order to test if the light source would be good to be placed somewhere else.

Here I was using sand paper cellotaped to a block of pine wood and sanding down the inside walls of each mountain panel in order to get a smooth finish after filling it down (it did not matter if all of the laser burns were sanded off due to each panel being primed and spray painted over.

This was glued the back ground mountains to the foreground mountains by applying PVA (Polyvinyl Acetate) along the top, bottom, sides and the sections of the mountains then apply to the back of the foreground mountains and rest of the panels, following this wait for 30 seconds to a minute for PVA to become tactile, then attach together and use G-clamps and hand clamps in order along all the sides of the glued panels along with the mountains to ensure a tightly glued panel piece. (repeat with all panels) wait to dry (solid stick is 24 hours).

Visual QC check to ensure my progress of work step by step.

Visual QC check to ensure any other possible locations for the light and if it suits the product.

Visual and Physical QC check to ensure that all the inside walls of each panel was to a high quality and smooth with no rough sections or edges.

Visual and Physical QC check to ensure that product pieces are in line and dry.

There are no health and safety issues.

Ensure that the electrics are all wired up and keep moisture away from electrics.

Take care when sanding to avoid any knocks, cuts or grazes to the fingers or hands due to the rough sand paper or rapid sanding motion.

Take care when gluing and keep feet away from possible dropping of clamps due to heavy weight along with keeping the glued pieces in an area out of the way from any further dangers.

After using the belt sander to sand down the tops, bottoms and sides I then used a tri-square to check the corners to ensure a perfect 90 degree right angle was achieved along with the top, bottom and sides were all straight.

Once the panel pieces were sanded down I then glued the laser cut star back panels to the back of the background mountains using PVA and then used G-clamps and hand clamps to get a tight stick (wait 24 hours for a solid fix).

After each laser cut star back panel was glued I then used a scriber to mark our where the very back panel needed to be sanded down using the belt sander in order to fit with the other panels in terms of length of width. After that I then used a smooth tooth file to sand down any rough sides or edges.

In addition I started to work on the embossing aluminium mountains by gather a sheet of tracing paper, tracing round the surface area I was going to eventually apply embossed aluminium to. Then cut out traced image using a crafting knife. Following trace outline of image onto paper for a harder template. After this then trace round paper template onto aluminium sheet.

Visual and Physical QC check to ensure that all sides and corners were perfectly accurate.

Visual and Physical QC check to ensure that the back panels are evenly in line and glued properly.

Visual and Physical QC check to ensure all perfectly in line and smooth quality finish after.

Visual QC check to ensure that the traced out image is to scale and its perfectly traced out for high accuracy and quality.


Take care when gluing and keep feet away from possible dropping of clamps due to heavy weight along with keeping the glued pieces in an area out of the way from any further dangers.

Take care when using the scribe so no injuries are caused due to sharp point. Wear goggles and apron when using the belt sander, also take further care when using file.

Take care when using the crafting knife due to sharp blade being used.

Manufacturing Log 3

Once the traced out image has been applied to the aluminium sheet, I used a fairly sharp pencil to emboss a design of my choice within the traced out mountain image.

Once the aluminium mountain image has been embossed, I used Stanley knife to cut out the outline of the image. (I repeated this process but with a different design and outline for the other panel that was requiring embossed an aluminium design.

This was the mould that I created myself but also with help from west Wirral work. I bolted the mould pieces together in order to get a solid mould, following this I then gather an ingot of pewter, sawed a piece off using a hack saw, then due to extreme tools being involved with heat and molten pewter, my teacher cast the pewter in the mould because I had no experience. After that I waited for the pewter to dry.

After the pewter has been cast, I used wet and dry paper and sanded down the pewter circle in order to get it to this quality surface with no dense scratches and a smooth surface. Also I used a file to sand down any rough/sharp edges round the pewter.

Visual and Physical QC check to ensure high quality with embossed design.

Visual and Physical QC check to ensure embossed design is to high quality along with the outline of the mountain image.

Visual QC check to ensure that the ingot is to a scale the pewter can be cast from.

Visual and Physical QC check to ensure that the pewter is to high quality.

Take care when handling aluminium sheet due to possible injuries cause by sharp edges from the aluminium.

Take extreme care when using the Stanley knife due to an extremely sharp blade being involved. (keep fingers away from blade)

Take care when sawing the piece of pewter off the ingot. Take care when handling the pewter’s sides so no injuries are caused.

Once the pewter circle has been sanded all around, trace out a circle using a compass and tracing paper to get a accurate reading of where to sand the pewter sides curving to, after use a small metal file to sand the sides curving through to the front face in order to create a 3D spherical effect.

I then compared the traced out circle to the filed/sanded pewter circle in order to gain an accurate result on making sure that it was all to scale.

This was the result after the sides of the pewter circle had been filed curving through to the front face. Once filed, use wet and dry paper further to gain a clean, smooth result.

Once the pewter circle has been completely checked for quality and accuracy, I gathered some wire wool and very fine/smooth sand paper and rubbed/sanded the pewter till the surface on the front face and all around sides are to extreme quality, I then polished it with some damp cloth for a better result.

Visual and Physical QC check to ensure that the pewter circle is to high quality and evenly filed.

Visual and Physical QC check to ensure high quality and accurate reading.

Visual and Physical QC check to ensure high quality with the surface of the pewter circle.

Visual and Physical QC check to ensure that the pewter circle is to high quality with the smoothness with surface.

Take care when handling the mall metal file due to rapid filing motion, may cause knocks, cuts or grazes on the fingers or hands.

There are no health and safety issues. There are no health and safety issues. When handling wire wool take care with fingers due to being sharp on skin when pulling apart.

Manufacturing Log 4

Once the pewter circle was sanded down to a fine surface, I then gathered a series of hole punchers in order to get different sized textural holes that I then hammered into the pewter moon (not too hard).

Finally I then blew any excess pewter out of the holes I punched. In addition I used a high chrome polish and rag to create a high quality finish on top of the pewter circle.

After gathering the required spray paints and materials I needed, I decided to test my technique and newly bought spray paints on the excess materials as a test in order to see if these sprays were suitable for the final product.

After spraying both light and dark grey on to the excess materials and waiting 2-3 hours for the paint to dry this was the outcome of the textural sprays.

Visual and Physical QC check to ensure that the texture of the hole puncher was to high quality.

Visual QC check to ensure that the quality of the high chrome polish was my standards.

Visual QC check to ensure that the whole surface was covered by the spray paint.

Visual and Physical QC check to ensure that the paint was dry and to completely covered to get the full effect and result.

Keep fingers away from hammering area to avoid any injuries.

Try not to inhale due to high chrome polish being a low solvent.

I wore a face mask, goggles and apron while spraying the excess materials with the spray paint inside a switched on spray booth with all windows around open.


For this part I started to wrap the back and foreground mountains in masking tape in order to avoid any spray paint going over them. I did this for every panel.

After masking taping them up I then used grey spray priming paint to cover the whole sky (top, and sides). I did this for every panel and waited for the spray primer to dry (20 minutes each panel).

Once the grey primer is applied and dried, I then used a matt black spray can to cover each sky on all the panels completely. I did this on every panel sky and wait for them all to dry (1-2 hours each for a dry result).

Once the sky on each panel was dry I then use white and blue spray paint to gently create a gradual amount of detail for the sky to give it a more galaxy effect. After applied I waited for it to dry (10-20 minutes).

Visual QC check to ensure that all parts of the mountain tops were covers to avoid any spray paint going over them.

Visual and Physical QC check to ensure that all parts of the sky and sides are covered enough and to ensure that they are dry as well.

Visual and Physical QC check to ensure that all parts of the sky on every panel is covered black and dried properly.

Visual and Physical QC check to ensure that the spray paint was dry and to high quality.

There are no health and safety issues. I wore a face mask, goggles and apron while spraying the excess materials with the spray paint inside a switched on spray booth with all windows around open.


Due to the lack of spray fumes I did not spray this in the spraying booth, I did however have all windows open and wore a face mask, goggles and apron.

Manufacturing Log 5

After the gradual white and blue spray paint was applied I then added a small amount of green, purple, dark blue and yellow to the sky to get a further galaxy detailed sky but using a very small tipped paint brush.

This is where I started to work on the tree panels. For this I primed each tree panel with a white spray priming paint and waited for it to dry (20 minutes each tree panel).

While waiting for a delivery from west Wirral works on some last minute adjustments. I received my package of 5mm MDF back extension, repeated the process of gluing them, sanding them insides and outsides down, marking out the excess with a scriber and then sanding them down to the exact size.

For this I collected regular beach sand (filtered any other bits out) applied PVA to the MDF mountains, then added the beach sand sprinkled over. Waited for it to dry, then repeated the process until I was happy with the aesthetics.

Visual QC check to ensure that the extra paint detail has been applied to a high quality standard and isn't displeasing.

Visual and Physical QC check to ensure that the all tree panels were completely covered and that they were properly dry.

Visual and Physical QC check to ensure that the back extensions are all the same size after sanding, no rough edges along with no damaged to them and then to ensure that they are glued in line and dried properly.

Visual and Physical QC checks to ensure that the PVA and sand is applied successfully along with drying properly.

There are no health and safety issues. I wore a face mask, apron and goggles and I sprayed this in the spray booth on top of some offcut cardboard. I also had the spray booth switched on and all windows open.

Goggles and apron worn when sanding down the back extension panels. Heavy duty footwear worn in case of heavy objects falling (G-Clamps).


After the sand was applied and dried successfully I then applied the textural spray paint (light grey) to the background mountains on each panel with numerous coats to make sure there were no unfilled gaps. Following this I also sprayed the foreground mountains with the darker grey spray paint that weren’t having aluminium applied.

For the two foreground mountains that were having aluminium included on them, once gathering the already embossed and cut out applying PVA glue to the surface the aluminium was going to be attached to. Following this I then collect some black and white acrylic paints, mixed them together to create a load of different shades of grey.

After applying most of the darker colours/shades I then started to work into it more with lighter colours/shades in order to create a detail realistic mountain look for aesthetical please.

Here I have gathered the tree panels, applied compressed mess on top of PVA (repeated until pleased) to capture the textural aesthetics and feel. In addition to this I also applied white spray priming paint in order to aid further detail with paints.

Visual and Physical QC check to ensure that the spray paint was applied properly and look aesthetically pleasing along with ensuring that the spray paint is completely dry.

Visual and Physical QC check to ensure that the paint was being applied to a high quality standard along with the paint being dry enough to apply another colour/coat.

Visual and Physical QC check to ensure that the paint was being applied to a high quality standard also to check if the paint was dry and the product was able to be moved/handled.

Visual and Physical QC check to ensure that the compressed moss is applied to high quality along with ensuring that all PVA, compressed moss and spray priming paint is dry.

When spraying the mountains I wore a face mask, apron and had all windows open surrounding the spray table.

There are no health and safety issues. There are no health and safety issues. I wore a facemask and apron when spraying the white priming paint in the spray booth on top of cardboard with all windows open.

After all mountain panels were painted/detailed with all textural appliances I then spread PVA glue along the foreground mountains and along the side and top outer frame. I then waited 30 seconds-1 minute in order to let the PVA become tactile, I then gather the front free panels and attached them all to each piece and collected the G-clamps and laid them on top of the attached panels. Wait to dry (24 hours for solid stick).

Once the tree panel was applied and dried I then worked into it with different hades of green, brown and black. The black was to cover the thin strips running along the top and sides of the panel. the brown was for the tree trunk. And finally when painting the trees I used 2 types of brushes (small/medium) in order to capture all cracks and crevices. The different shades of green came in handy to create further more interesting detail on each tree which was also painted with different detail each time to make it more bespoke like the rest of the product.

Once dried I them started to work on the hardwood mahogany framework. This I marked out the size (length and Width) following my teacher cutting them down on the bansaw for a quick and easy result. In addition I then used the try square and adjustable sliding bevel to mark out a perfect right angle. In addition I then used the mitre saw to cut the right angle without any struggle, then using the bansaw I sanded down the rough edges so there would be no hassle when gluing them all together.

This is where I used a lot of PVA to glue all around the panel pieces (only to a certain width to avoid a messy PVA being squeezed to the surface through the join of the hardwood and MDF panel pieces.

Visual and Physical QC check to ensure that the tree panels were attached properly. In addition checking that they were inline and dry after waiting.

Visual and Physical QC check to ensure the paint is applied properly and detail is to high quality standard in addition to ensure it is all dry.

Visual and Physical QC checks to ensure that the hardwood framework is cut 100% accurately along with ensuring the wood is not damaged or rough on the edges.

Visual and Physical QC check to ensure that the hardwood framework is applied properly and is inline with the panel piece. Furthermore to ensure that the hardwood is strongly stuck.

Heavy duty footwear worn when handling this stage due to heavy weight clamps.

Apron worn when painting to ensure that the clothes I wore were not damaged.

For this I wore an apron, goggles and got assistance to cut the wood on the bansaw due to myself not being qualified or experienced.

Heavy duty footwear worn when handling G-clamps in case of any falls due to clamps being heavy which could cause injury.

Once all the hardwood framework on every panel piece was attached and dry, I then used the belt sander to sand down the top layer of the hardwood. Following this I then applied a wax finish to make the hardwood framework look more aesthetically pleasing. After the wax had set into the Mahogany framework I then used some wire wool to take a thin layer of wax off the framework and make it smoother.

This was the back panels that had sanded down to size, marked out how tall the battery pack was and cut a slot using a coping saw and file for the battery pack to be visible so the client was able to access the On/Off switch. In addition to this and smoothening any rough edges off I then primed the back panels with white priming paint and waited for it to dry. Furthermore I gathered a clean roller and applied black acrylic paint (series of coats till fully covered).

For this I measured how long a strip I would need for the woven loops on the battery pack. Furthermore I then copied the same length for the plastic hook strip of Velcro which I then attached to the back of the middle panel where the battery pack was going to be combined. After doing this with all panel pieces I then attached each battery pack wires with the corresponding positive and negative slots on an 8 LED silicone strip that I secured with a small piece of masking tape and then used PVA to glue the LED strip where it lined up with the laser cut stars to shine through.

Here I tested different drill sizes to fit the specific screw thickness I was using. Following this I then gathered my back panels and marked out where they where going to be drilled and drilled holes into the marked spots with the correct drill bit and then placed each panel in the correct panel piece. Furthermore I then used an Bradawl to mark out holes in the MDF back extensions in addition I used a counter inking tool which enabled me to insert the screws properly without any of the screws sticking out. I then screwed the using a screwdriver.

Visual and Physical QC to ensure that the wax was applied properly and then to check if the wax had been smoothened down to a none slippery surface.

Visual and Physical QC check to ensure that the paint was sufficiently applied along with drying properly.

Visual and Physical QC check to ensure that the Velcro was applied successfully along with attaching the battery wires to each LED strip and so ensure all was glued and attached properly. in addition to ensure it lit up properly.

Visual and Physical QC check to ensure that the holes drilled are accurately placed. Also to ensure that everything marked out and drilled is completely accurate.

There are no health and safety issues. I wore and apron and goggles to be safe when cutting out a slot for the battery pack and when painting the panels.

I took care when handling the electrics in case of any electric shocks.

I wore goggles and an apron and tightly tucked any loose clothing away to avoid anything getting snagged, I also clamps down the test piece and sealed the pillar drill guard over.

Manufacturing Log 6

After all was finished with gluing and tightening, I then only needed to touch up the final bits that had scratches and a lot of sawdust over it.

Here is everything all touched up and finalised.

Visual and Physical QC check to ensure that the finished product has been completely touched up and is completely dry.

Visual and Physical QC check to ensure that the finished product is 100% complete with no missing pieces that haven’t been painted or unglued. To ensure as well that the product has no rough edges or sharp points and is smooth throughout the top, bottom and sides of all the hardwood casings.

There are no health and safety issues. There are no health and safety issues.

Manufacturing Log 7

Conclusion: I conclude that over the course of manufacturing this product I have been able to look at it from different perspectives and to adjust the product if necessary. There are a couple of modifications that I would make with the lighting and aesthetical features of it however I am very pleased with the outcome.

Final Product

Product Evaluated against Product SpecificationSpecification Does

MatchDoesn’t Match

Reason


Yes The Product features a screw in based backing on each casing which reveals a adhesive LED strip attached to a 9V battery pack that is veclrod to the middle stars/sky panel.


Yes Each LED strip shines through laser cut stars and hand drilled holes that are located in the middle panel of each casing.

3. The lighting product will be designed so that it is portable and can be utilised in any suitable area.

Yes The product contains a 9V battery pack on each casing with an ON and OFF switch, this gives it portability. In addition, each casing is separate and has no attachments to each other. The hardwood casings around each panel give it suitability in any indoor stressful environment.

4. The light product will be based on an organic theme. Yes The product is based on a mountain/sky feature that holds intricate detail and texture throughout, along with tree panels with further textural detail at the very front of the product in order to capture the further organic theme.

5. The outer body of the product will be easy to clean, by simply using a wet wipe/cloth.

Yes Because the product includes a hardwood casing around the outside which is varnished with a wax finish. This gives it a quick and easy way to clean the product. However due to the intricate detail that is inside the product casing, all it needs is a little wipe to carefully clean it.

6. The product will be original. Yes Because the product is based on my own design that I have developed from the other ideas. In order to get this final design. Ideas and points from my client have aided in the creation of an original product.

7. The product will have a specific colour scheme. Yes The product contains a colour scheme of my choice that meets the tastes of my client and also a classy style that suits the design of the product.


Yes The product includes a cast pewter moon along with multiple laser cut designed panels.

9. The product will be manufactured for my mum (client) Yes Due to my client needing a new light/lamp I have designed the product for her to replace the old broken one.

10. The product will be manufactured to a high standard by carrying out QC checks at all stages.

Yes During the process of manufacturing the product, I have carried out quality control checks during every stage to ensure high quality and accuracy for the finished product.

11. The product will be used in the living room. Yes Due to my client needing a new light/lamp for her living room I thought it was a good idea to base my DT project on a new light/lamp for her that she is able to have her own input into the design for her own tastes.

12. The product will be safe during use and miss-use. Yes The product includes a simple On/Off switch located on a battery pack that is also located in the back of each product casing.


Yes The product consists of offcuts from MDF sheets and other offcuts for different materials. this gives it no environmental issues along with all consisting of recyclable materials such as aluminium and MDF however the use of Mahogany hardwood did come at a higher expense due to it being a hardwood

14. The product will interoperate components that have been manufactured by using CAM.

Yes I have used CAM to design a series of mountains and trees along with a sky full of starts by having them processed and laser cut at west Wirral works.

Conclusion: I conclude that after evaluating the product against the product specification it is clear to see that it met all specification points. Throughout the manufacture of my client’s light I rigidly stuck to the specification because I wanted to ensure that I hade made sure a high quality product that would look professional.

Product Evaluated against client Specification

Specification Does Match

Doesn’t Match Reason

The client would like the product to include wood and metal.

Yes This is because my client likes the textures that can be achieved on wood and metal such as embossing aluminium, filing/sanding down to gain 3D detail/texture.

My client’s favourite theme is floral. No This is because my client likes the outdoors and scenery.

Natural and organic forms such as leaves, trees and mountains.

Yes This is because my client enjoys going for walks in the outdoors and looking at beautiful scenery also inspired from the artwork picture throughout her house.

Relaxing and peaceful imagery. Yes My client likes to relax from a hard days work and due to the already existing imagery in her household, she requires further relaxing pieces.

Shades of green and metallic pinks and purples.

Yes My client is a female and finds brighter colours more appealing along with her love of the outdoors and scenery. Different shades of green is also an appeal to her. Also there was a small amount of purple used in the sky for the final product.

Separate panels. Yes This point is inspired by her already existing art piece in her living room as also stated an analysed in the client profile.

Conclusion: After evaluating the product thoroughly against the client specification it is obvious that 99% is a match. This means that I have successful met five out of six of my client’s needs the point that did not match was not a major attribute because my client had repeatedly requested mountain scenery because she found it intensely relaxing after work. Finally if I had more time I could of incorporated detachable slots or panels in that were based on a floral theme of some sorts.

Evaluation-My ClientThis is my client. She has tested the final product I have created designed and manufactured for her. She is very pleased with the final outcome of it and is looking forward to placing it in the desired spot of her choice (Livingroom on top of her hardwood table in the corner by where she sit.

This is my client testing out disassembling the product by unscrewing the back panel of one of the lighting cases in order to reveal the inside of the power supply to become familiar with it along with understanding how it is constructed for future references.

This is where the lighting product will be placed for my client.

Likes Dislikes Improvements“I like the colours that are included/ the detail with whole overall product, to the mountains in the back and foreground to the trees. I feel that the product is very well constructed and I like the large/tall scale of the product. The fact that It is a split piece is very intriguing due to the fact it can be separated and placed in whatever order I may like. Furthermore the light switches are neatly tucked away inside the back of each product piece. Finally the lighting mixed with the laser cut stars creates a sense of relaxation which I feel is what I like to look for when decorating the Livingroom.”

“I do no have any dislikes to the final product.”

“I think that the lighting product could include a colour changing LED that could either flash or sparkle/twinkle.”

These are 2 pictures each from a different angle showing my client switching on the lights on from the back of the product testing it.

This is the product being tested in the dark to check the amount of light it generates in the area it was designed for.

As shown in these two pictures to the left, I have tested the final product in the home of my client’s in different areas. This being in the area it was designed for, and on the floor where she used to have one of her older lamps.

Conclusion: if I was going to re-create this product I would follow my client’s suggested improvements in order to meet my client’s tastes.

Evaluation-Other ClientsClient Likes Dislikes Improvements

Adam Price

“I liked the textures (rocky mountains) this is because of the 3D effect. The detail on the night sky is very unique because it captures the stars in the sky and includes multiple colours for possible different planets etc. the finish used on the hardwood is very aesthetically pleasing. The tidiness with the power supply is neatly tucked away. The continuous layout is very interesting with the variety of different materials included (MDF-Aluminium-pewter) one of the most unique things I particularly like is the use of detail in the foreground compared to the background with the mountains. Another one of my favourite features is the paintwork on the whole product, this being specifically the rough textural detail on the background mountains then moving forward to the drybrush effect on the foreground mountains.”

“The LED strips are visible through the laser cut holes where the light shines through.”

“The product would be better if it used single LED bulbs behind each star-hole. You could put and LED strip under the top of each frame so the mountains become more visible in the dark (LED strips could be blue for mood lighting).Acrylic mirrors could be set behind scenery to reflect light, this would distribute the light more on a larger scale.The finish on the moon could have some dark lacquer shades added for further detail.”

Debbie Price

“I particularly like the contract of colours of the metal moon against the dark sky. The star shapes that are cut out are very relaxing. The star clusters and diamantes acting as sparkling stars were very unique and captured the stars in space very well. Various textures used is makes the product very aesthetically pleasing and with the smooth hardwood finish including the grain on the outer casing is a lovely touch and gives the product that little bit extra because of the contrast with the dark inner case going against the lighter outer case.”

“No Dislikes” “The product could include brighter lights (more lights or laser cut stars). Also different themes could be created for children (the likes of fairy themes e.g. dogs around the tree bases, or toadstools etc.”

Evaluation-Other ClientsClient’s Evaluating Clients testing/

disassembling product

This is one of my further clients Adam, he is evaluating the product on what his likes, dislikes and improvements are on the final product.

Here is client Adam testing out the product by switching on the light switch located on the back of the piece. It is not within too much distance of stretching and did not strain his body.

This is one of my other further clients Debbie, she is evaluating the product on a form I created for her likes, dislikes and improvements to the product.

This is client Debbie disassembling the product In order to reveal the power supply and light source. She did not find it straining or difficult to unscrew the back panel and detaching the panel from the back of the piece.

Conclusion: I have done this evaluation with more detail on what my further clients did with the final product e.g. evaluating, testing and disassembling. This proved effective because It enabled me to get a more accurate results on how other clients find the handling and replacing of the power supply of the product.