Custom Fixture
This project was contracted by the WeWork Manhattan office. The goal of the project was to integrate a new technology from Ecosense into an existing lighting fixture that is present throughout all WeWork offices nationwide. I was given several filament-bulb fixtures and tasked with driving the project from concept to completion.
PLANNING
After taking apart existing fixtures to understand each component, the key design considerations were determined to be customer specifications, weight of fixture, tensile strength of materials, thermal performance, and overall aesthetics.
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Initial plans involved basic machining and milling, modification of heat sink, rewiring of LED modules, and introduction of custom parts.
FINAL
The final product includes production-grade custom parts designed in SolidWorks Sheet Metal and procured from an international vendor. The entire fixture was evaluated using load, thermal, and CCT testing. The final two fixtures were sent to WeWork Manhattan.
MODIFICATIONS
The heat sink was modified to allow wires to run through the center, hiding them from customer view. Later testing proved that milled channels did not provide enough thermal contact area with the heat sink. Fixture installation was improved with a series of brackets, spring-release parts, and a load-bearing steel cable.
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Wires were initially lengthened by solder and heat-shrink, but later replaced by a premade coaxial cable to increase robustness of design. To increase strength of electrical connections, several different styles of clips were tested for use between the driver box and LED module.
Mechanical Engineer
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