T - bulb prototype
Create a new form factor that combines minimal aesthetics with enhanced functionality. The design aimed to achieve smooth 300-degree horizontal and 360 vertical rotational movement while maintaining a compact, premium form suitable for modern interiors.
Project Details
Brief, Materials, Process & Validation
Design Scope & Functional Targets
The T - BULB prototype project was commissioned to evaluate industrial design ergonomics, aesthetic proportions, and mechanical assembly feasibility before high-volume tooling. The brief specified an elevated brand aesthetic, intuitive operator touchpoints, and structural ribbing engineered for production manufacturability.
Engineering Materials & Surface Finishes
Fabricated using production-intent engineering materials: Plastic. Key structural enclosures utilize vacuum-cast flame-retardant polyurethanes with custom CMF satin finishes, paired with precision CNC-machined metal fasteners and wear-resistant bushing inserts.
Model Making & Rapid Tooling Workflow
The prototyping process utilized high-precision stereolithography (SLA) 3D master prints for dimensional fit checks, followed by room-temperature vulcanizing (RTV) silicone tooling. Parts were vacuum-cast to achieve uniform wall thickness and sharp character lines, followed by hand-sanding, priming, custom metallic CMF painting, and UV-cured topcoat.
Quality Benchmarking & Ergonomics
Validation protocols included mechanical drop and vibration testing, continuous duty-cycle thermal airflow logging, parting line alignment checks under simulated operating loads, and tactile feedback evaluation across targeted user cohorts to confirm production readiness.
What We Set Out to Solve
Designing a new internal mechanism to enable smooth and reliable 300-degree rotation Maintaining dimensional accuracy and structural stability within a compact form Designing a new internal mechanism to enable smooth and reliable vertical 360-degree rotation Integrating lighting components without compromising rotation or heat management
How We Approached It
Developed a custom rotational mechanism allowing controlled 300-degree movement Optimized internal geometry to support rotation and component integration High-precision SLA 3D printing for accurate fit and smooth surfaces Refined post-processing for a production-like premium appearance
From Concept to Completion
The complete prototype development journey for this project.
SLA-ABS RPT – 3D Printing
Prototype parts are 3D printed using ABS-like material based on the final design. This stage creates accurate parts for size, fit, and overall evaluation.
Post Processing
Printed parts are cleaned and support material is removed. Surfaces are refined to achieve a smooth finish before painting.
Final Painting & Surface Treatment
Parts are painted to match the required color and surface finish. Surface treatment enhances appearance and visual quality.
Assembly
All finished parts are assembled into a complete prototype. Final checks are done to ensure proper fit and alignment.
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