Project Description

Unique Lighting Solution

John from Newton Lighting Enterprises needed a custom solution for his soft lighting product line. John had an existing extrusion that he was using for his product but he wasn’t happy with it and wished it provided him with better features. We sat down with him and went over his requirements which included the ability to fit an existing plastic cap and existing plastic screen, have a flat internal surface for better LED mounting, and to allow for a bracket mount with an adjustable pivot. Once the redesign started, we worked closely with John and listened to his feedback to come up with the perfect design that hit all his criteria. During the design, we presented John with a bonus feature for his extrusion system, an extension system using pins which now allowed him to connect multiple extrusion pieces together and now create a lightning solution of unlimited lengths, something that his competition does not have! Once the design stage was finished, we created a set of plastic prototypes using our state of the art 3D printing system so John could hold his future product in his hands and provide us with feedback on it’s fit and function. After we’ve received his approval, we created the required manufacturing drawings for him and submitted them to our aluminum extrusion supplier to be manufactured in multiple colors and finishes. We also created a marketing flyer and a few high-def renders for him marketing team to help show off the product. John and ourselves are very happy the way the product turned out, you can now find this product offering on the NLE website.

Reception Desk Application Render made for Newon Lighting Enterprises

Skills Needed

John’s project required a multi skilled approach to fulfill its requirements. The previous extrusion design had to be analyzed and reworked to meet the customer requests and the aluminum extrusion process requirements.  Prototypes were made to perform a hands on examination of fit and function. Drawings and 3D models were created to provide to the manufacturer for a production run. Brochures and other graphics material was created to help John with his product exposure and marketing.

  • Understanding Customer Needs

  • Engineering

  • Prototyping

  • Manufacturing

  • Graphic Design

Before and After

Corner Extrusion Redesign

Features:

Flat Surface for LEDS – Allows for easy assembly

Pivotable Bracket Mounts – Provides adjustability during installation

Extendable Extrusion System – The system to be any length

Uniform Wall Thickness  – Easier manufacturing and cleaner finish

Better Surface Aesthetics  – Better looks and smoother surface

Accepts Old Plastic Cap – No need to invest into a new cap

Accepts Old Plastic Screen  – No need to invest into a new plastic shield

Square Extrusion Redesign

Features:

Screw Mounting Area – Allows for easy installation

Drill Assist – Provides for easy drilling on-site

Free Space for LEDS – Creates open space for insertion of LEDS

Uniform Wall Thickness  – Easier manufacturing and cleaner finish

Better Surface Aesthetics  – Better looks and smoother surface

Accepts Old Plastic Cap – No need to invest into a new cap

Accepts Old Plastic Screen  – No need to invest into a new plastic shield

Prototypes

Prototypes are indispensable in saving time and money as they provide invaluable direct feedback and allow for instant fit and function testing. We made multiple prototypes for John to test his product and provide us with feedback.

Manufactured Extrusions

John decided to have his product come in two finishes, glossy white powdercoat and matte satin clear. The final aluminum extrusions came out very well and are cut to custom lengths.

Final Product

The new extrusions are in and the final product is assembled and looks great!

“Mr. Sivak,
Although your services and skills came highly recommended, you never truly know until you engage and when it comes to a persons livelihood there is little room for poor judgement in vendors. You need people that not only have the skills, but who truly care to design the best product for their clients. You have absolutely portrayed both to myself and product!
When I came to you with my idea, I really had no idea how good the final design and product would end up. The process started with you listening to what I wanted to accomplish, in the middle you verifying, correcting, suggesting, and ended with a product I am very proud of. With the quality of drawings, renderings, and 3D prototyping you provided along the process there is no doubt you shared my vision and brought it to life.
I would not be where I am today with out your service and caring, looking forward to our next project!”

Render Gallery

Here are some of the renderings and graphic art we did for John to help with his product exposure, marketing, and social media.