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Finite element analysis became an integral tool to managing many of the initial design hurdles. Using feedback from the simulation software I was able go to the ID team and rework the design. This dialog between industrial design, engineering, and manufacturing was crucial to the early success of the project.
The multifarious parts in this design required a diverse use of manufacturing techniques including; aluminum die-casting, sheet metal formation, injection molding, and wire bending, among others.
During the test process we used a number of prototyping methods including additive manufacturing and machine samples. This was important to verify certain functional aspects of the design as well as approve the visual styling.
One of the more technical aspects of this project was the design of the removable driver tray. Multiple design prototypes were created to address the functional and thermal issues.
Pictured here is one of the initial test samples set up in our model shop. The final design, in it's highest power configuration is expected to produce an output upwards of 20k lumens in a package smaller than a milk crate.
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LED Wall Sconce

A high power, LED wall sconce designed for Gardco-Philips. I was the lead engineer for this project during the spring and summer of 2012. The goal of this project was to design a high output wall fixture to fit in with Gardco's current line of LED luminaires. A primary consideration with this project was to manage the relationship between engineering and manufacturing while still keeping the industrial designer’s vision intact. As this product is yet to be released, I am not permitted to show any full product renderings or photos of the completed design. This product will be released early 2013.

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Jacob Rader
Design Engineer Austin, TX