Array
Array is my final year major project.
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Array is a modular lighting system aimed at amateur mechanics to improve safety and workflow.
The main insights for this product were gained from a restoration project undertaken in the summer of 2020 where I gained a wealth of knowledge and experience, this led to finding countless issues that all stem from poor lighting and visibility.
Graduation Design Portfolio Download:
The system is comprised of 3 different lighting fixtures, 3 different attachment mechanisms, 2 4400mAh Li-Po battery packs, the main body, and a charging/ storage box. The modular system allows the user to customise the light to fit any given situation in an automotive setting; be that welding or replacing brake pads.
The charging/ storage box houses all of the systems components and allows the batteries to be charged whilst in storage, a 3 pin collapsible plug is stored under the foam inserts as well as the USB type C cable
Foam models were made to get a physical form, these allowed me to test how the light systems may be used and to get a sense of scale for the overall product.
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The models were also given to a professional mechanic to see how they might change the design to fit their workflow.
Array uses Arnitel TPC as the over mould, to cope with the harsh environment tools are subject to. Nylon PA66 GF 30 is also used for the main substrate to make for a rigid and hardwearing product. Die-cast aluminium is implemented for the mechanisms to allow for a strong/ reliable connection.
Testing using other lights on the market proved a useful exercise to pick out any flaws and develop upon them.
I also used the existing lights to gain an understanding of what materials were used and how the manufacturers had achieved unique features such as the ratcheting handle/ base components.
It was also useful to spot possible weak points in the original designs such as having pivot points on mould lines which are likely to wear and become loose, this also make for a weaker connection as the ABS in this case is not homogenous around the pivot.