Skeletal LED Desk Lamp

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Skeletal LED Desk Lamp

Date Created: March 2016

Collaborators: Monty Lackey - Machinist Mentor

Location: Warsaw, Indiana

While working at Zimmer Biomet, I was given the opportunity to design, machine and assemble a project of my choosing. I chose to design an adjustable LED desk lamp. It consists of 19 machined and anodized aluminum parts as well as two 3D printed titanium parts. In addition to constructing the framework, I also integrated a dimmer switch into the circuit. I used a lathe, wire EDM, end mill, 5-axis mill, sand & ceramic blasters, and a variety of polishing wheels to obtain the finished product.

Coffee Table

Design Progression

Coffee Table

Date Created: June 2014

Collaborators: N/A

Location: Los Angeles, CA

Project Breakdown

Motivation

I woke up early on a Saturday morning in June 2014, glanced at the aging, fragile Ikea table in my living room and decided it needed a replacement. I decided it'd be fun to design one myself, so I set a spending limit, a maximum tabletop area, and a time limit and got to work. The goal: to design and construct a coffee table with maximum tabletop dimensions of 2'x2' in one day, spending no more than $200.

Summary

I created a rough schedule describing how many hours I would devote to each portion of the project. I spent a couple hours researching ideal materials and design ideas that met my set design requirements. I used this research to drafted some rough designs concepts for the table, which took about 3 hours. Next, I created a detailed CAD design and headed to a local hardware store to purchase the necessary materials. I spent the remainder of my time staining the wood, and constructing the table.

Schedule

Recognize Limitations: 0.5 hr
Research Solutions: 2 hr
Draft Multiple Design Concepts: 2 hr
Detailed CAD Design: 3 hr
Purchase Materials & Locate Tools: 2 hr
Construct Table: 7 hr
Discretionary: 7.5 hr

Design Requirements

$200 Budget
Durability
Stability
Light Weight Materials
Aesthetics
2'x2' Maximum Tabletop Area

Research & Solutions

Durable, Light Weight Materials
- Aluminum & Wood
Stability
- Symmetric Geometry & Even Weight Distribution
Aesthetics
- Cherry or Mahogany Stain & Exposed Fasteners/Supports

Design Concepts

CAD Design

Symmetry
Lightweight
Affordable
Within Size Limitations
Optimized Support
Basic Tooling

Isometric Rendered View

Isometric Exploded View & Bill of Materials

Right Side View

Ride Side Exploded View

Front Exploded View

Top View

Top Exploded View

Bottom View

Bottom Exploded View

Necessary Materials

Aluminum Legs, Brackets, Braces, Nails, Sheets
Wood 2x4 Planks
Stainless Steel Screws
Mahogany Stain
Rubber Feet

Necessary Tools

Power Drill
Circular Saw
Hammer
Paint Brush

Completion

Coffee Table

Soundboard Lamp

Piano Soundboard Lamp

Date Created: July 2014 - August 2014 | Collaborators: N/A

Purpose: Recreational | Location: Los Angeles, CA

Function: Aesthetic Lighting

Materials: Fischer Upright Piano Soundboard, Stained Mahogany Wood Frame, LED Strips, Light Bulb Sockets, Wood Glue, Edison Light Bulbs, Brass Piano String

Retractable Bed Desk

Retractable Bed Desk

Date Created: January 2015

Collaborators: Tucker McWhirter

Location: Los Angeles, CA

Project Breakdown

Motivation

A colleague contacted me inquiring about designs for a retractable bed desk so that he could do work and watch movies in bed. The only customer-set limitations were the need for the desk to be retractable and for total costs to stay below the budget of $50.

Schedule