Prototypes help bring novel floodlight to market

When Blue-i UK set out to produce an industrial floodlight using the latest LED technology it commissioned Cube3 Creative Product Design to develop the concept and design for production.

When Blue-i UK had the idea to produce an innovative industrial floodlight using the latest LED technology it commissioned Cube3 Creative Product Design to develop the concept and design for production.

The battery box was designed to house a 12V lead acid battery with a minimal part count.

The design incorporates a top moulding in a super tough nylon and a Hytrel elastomeric base that soak up impacts.

The battery is cleverly mounted between the top moulding and the carry handle reducing the number of parts used and making assembly quick and easy.

During initial research it was identified that most users preferred the on/off switch to be mounted to the battery box and also that "There is a real danger of being stranded in an unlit and hazardous environment if the portable lighting unit runs out of battery life".

This problem was addressed by incorporating sophisticated electronics that monitor battery life and warn the user of low battery by strobing the lamp-head three times over a 30 minute period.

The solid state switching in the electronics allows the switch to be safely housed in the main battery box.

The lamp head had to be designed to house a ground breaking LED light engine developed in conjunction with Universal Science.

The heatsink required to dissipate the heat generated by the high intensity LEDs was too hot to be externally mounted and yet the component side of the light engine had to be kept dry.

A solution was found by sealing the component side of the light engine to the lens moulding and allowing the majority of the enclosure to be open to the elements.

The front and rear lamp-head mouldings also incorporate a hinge arrangement that allows 170 degrees of movement to the pole assembly that in turn allows the lamp to be raised to a height of just under 1m.

In addition the battery is capable of powering a second head which can be mounted on an optional tripod.

It was decided from the outset, that a series of prototype models would be required for evaluation and testing and once the concept was finalised, Cube3 approached Paragon Rapid Technologies, as it was familiar with the company's service and quality.

Discussions took place regarding the mechanical properties of the polyurethane resins and any possible limitations of the materials and further to considering other processes such as SLS, FDM and CNC, it was decided that vacuum castings from silicone rubber tools would be the most appropriate route and would allow the production of five full assemblies.

The master patterns for the main body and head were produced as stereolithography models, fully hand finished to include a "spark" texture.

The lens cover had to demonstrate good optical clarity and as the front face was completely flat, Paragon opted to fabricate the master pattern from acrylic sheet, with additional walls and details produced by stereolithography and grafted into place.

This ensured a perfectly flat and polished lens.

Silicone tools were produced from all of these parts and subsequent vacuum castings.

Consideration was given to the selection of PU resins, in order to achieve the required mechanical properties and temperature stability as well as allowing pigmentation to achieve the vibrant colours matched to RAL references.

The lens component was cast in a clear, high temperature, UV stable resin and all five sets of castings were supplied within 8 working days of receipt of CAD data.

In addition Paragon was asked to produce the rubber on/off switch.

Again an SL model was created as a master pattern, but a rigid tool was produced from epoxy to allow the moulding of silicone components.

However, in order to achieve the required feel and functionality of the switch, parts were eventually produced in a pigmented, 40 shore A polyurethane rubber, which incorporated overmoulded clear acrylic light guides and surface graphics.

Cube3 were able to assemble the units, fitting the light engines and battery and carry out full testing of the units prior to delivery to Blue-i.

In addition to field trials and testing, the units were so visually representative of production parts that full assemblies were used for the production of photographs for marketing and printing of product brochures.

Blue-i has exhibited the i-storm24 at a number of trade shows and exhibitions and subsequently have called off a further 10 sets of vacuum castings from the existing silicone tools.

These have included colour variations appropriate to specific market sectors, which have allowed targeted marketing and have demonstrated the versatility of the product.

The entire product has been taken from concept through prototype development to market with orders far exceeding expectations within a matter of months and all of this has taken place before initial production samples have been produced.

The i-storm24 brings the latest in LED technology to the portable industrial lighting sector.

"The final design is striking and robust, bringing design flair and innovation to this market".

Following its debut at Intermat 2006, the product has been received with great interest and enthusiasm from a very broad market, including the building industry, emergency services and the MOD.

Blue-i UK entered the i-storm24 into this years Buildings Health and Safety Awards and was shortlisted for the best safety product.

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