1. Designing Product Families – IVALO Lighting IVALO Lighting ME 597B Designing Product Families David EricsonMike Minnicino Nakhiah GoulbourneRyan Noss Andrew HoskinsJeremy Schadler

2. Designing Product Families – IVALO Lighting Presentation Overview Introduction Sponsor Background Project Goals Project Foundation Product Design Strategy Manufacturing Strategy Course Relevance Conclusions Future Work

3. Designing Product Families – IVALO Lighting Introduction Objective: –Investigate the customizability of a hanging light fixture for kitchen, home, and office use. –Develop CAD models and CNC machine prototypes in the following hull sizes: 3,4,5,6 ft

4. Designing Product Families – IVALO Lighting Sponsor Background “Dr. Hakkarainen is the founder of Ivalo Lighting Incorporated, a company that will produce premium decorative light fixtures for the residential and commercial market. Ivalo fixtures use cutting edge technology to produce advanced, high fashion designs that have superior optical properties and quality while maintaining ease of installation. Ivalo will feature designs from all over the world and is starting with Italian designs.” SUSAN HAKKARAINEN President, Ivalo Lighting Incorporated Source: Cornell University - School of Electrical and Computer Engineering

5. Designing Product Families – IVALO Lighting Project Goals An inexpensive and durable model is desired for display and design purposes. Develop a family of products ranging in size from 3-6 ft based on the original 4ft model. Use knowledge gained in Designing Product Families to create products that exemplify scale-based product families.

6. Designing Product Families – IVALO Lighting Project Foundation Ivalo provided an original 4ft prototype Original drawings for the prototype shape and other parts were also provided. Phone conference with Susan Hakkarainen outlined design requirements and changes.

7. Designing Product Families – IVALO Lighting Product Design Strategy Proportional Axis Scaling Non-Proportional Axis Scaling Attribute Scaling

8. Designing Product Families – IVALO Lighting Product Design Strategy Attribute Scaling Method LHR 361.25120 481.25160 602.125200 722.125240 Dimensions in inches L R H Revolved cross section

9. Designing Product Families – IVALO Lighting Product Design Strategy Why Use Attribute Scaling Method? canopy supports hull grill chassis end chassis center chassis Canopy, hull and center chassis are unique for each light. Supports and end chassis are identical for 3 & 4 ft or 5 & 6 ft models Grill discs can be used for multiple lights (3 & 4 ft or 5 & 6 ft models).

10. Designing Product Families – IVALO Lighting Manufacturing Strategy How Do We Make It? Find an inexpensive material that can be machined easily, that is cheap, and that is durable. –Plastic (PVC), wax, wood, metal Determine a quick and easy method for making the parts. –Machine using CNC machine, or Lathe –Make mold, final product (shell) or solid block

11. Designing Product Families – IVALO Lighting Manufacturing Strategy Preparation: 1.Design and CAD modeling 2.Tool path Generation Mold Creation: 1.PVC Preparation & Cutting 2.Gluing 3.CNC Milling 4.Rough Manual Milling 5.Sanding Mold Light Creation: 1.Fiber Glassing 2.Bondo Application 3.Bondo Sanding and Finishing 4.Edge Trimming 5.Painting 12 Step Manufacturing Process

12. Designing Product Families – IVALO Lighting Manufacturing Strategy Preparation: 1.Design and CAD modeling 2.Tool path Generation

13. Designing Product Families – IVALO Lighting Manufacturing Strategy Mold Creation: 1.PVC Preparation & Cutting 2.Gluing 3.CNC Milling 4.Rough Manual Milling 5.Sanding Mold

14. Designing Product Families – IVALO Lighting Manufacturing Strategy Mold Creation: 1.PVC Preparation & Cutting 2.Gluing 3.CNC Milling 4.Rough Manual Milling 5.Sanding Mold

15. Designing Product Families – IVALO Lighting Manufacturing Strategy Light Creation: 1.Fiber Glassing 2.Bondo Application 3.Bondo Sanding and Finishing 4.Edge Trimming 5.Painting

16. Designing Product Families – IVALO Lighting Manufacturing Strategy Light Creation: 1.Fiber Glassing 2.Bondo Application 3.Bondo Sanding and Finishing 4.Edge Trimming 5.Painting

17. Designing Product Families – IVALO Lighting Manufacturing Summary OperationAve Time/LightAve Cost/Light Design and CAD modeling Tool path Generation PVC Preparation & Cutting Gluing CNC Milling Rough Manual Milling Sanding Mold Fiber Glassing Bondo Application Bondo Sanding and Finishing Edge Trimming Painting TOTAL 45 min 1 hr 15 min 9 hrs 2 hrs 15 min 8 hrs 3 hrs 2 hrs 1 hr 45 min 30 min 2 hrs 1 hr 30 min 34 hrs N/A $ 350 $ 12.50 N/A $ 41 $ 8 N/A $1.50 $ 413

18. Designing Product Families – IVALO Lighting Course Relevance Course Question: How can product realization teams provide increased product variety at less cost for a highly competitive, global marketplace? How does this project tie into the class? IVALO Lighting Answer: Designing (scaling) a product carefully can allow manufacturers to create multiple products using common parts and take advantage of economies of scale.

19. Designing Product Families – IVALO Lighting Course Relevance Source: ME 597B (Designing Product Families) - Scalable Product Platforms

20. Designing Product Families – IVALO Lighting Conclusions An overall shape was designed for the 4ft. model. The design was scaled by scaling different attributes of the structure Molds were machined using CNC machines Fiberglass and Bondo were used to create 3, 4, 5, and 6 ft models.

21. Designing Product Families – IVALO Lighting Future Work Create remaining parts needed for working prototype: –Canopy, Grill, Chassis, Support Redesign for Aluminum (if needed)