loading
Picture of LED Light
DSCN3121.JPG
DSCN3122.JPG
DSCN3140.JPG
DSCN3144.JPG
DSCN3147.JPG
This is a KS4 Engineering project that my year 10's do (14 year olds). It gives the students choice and the opportunity to work creatively. The outcome is a quality product that works well, most importantly at the end of the project all the students will want to take their work home......empty work box = awesome project.

The students can choose either to make a desk light which is more functional, or a mood light which is more aesthetic. Check out the video to see how the magnetic switch adds extra awesomeness to the product.



Learning Objective

Students will design and make either a functional or decorative light. The design process reflects how professional design engineers work by teaching students creative designing skills to produce a unique and original design idea, and then how to make a virtual prototype using 3D CAD software. To stretch and challenge the students the project introduces more advanced measuring and marking skills, metal fabrication and forming, the properties of thermo / thermosetting plastics and how to manipulate their properties to make the design. The students will be introduced into basic electronic components and will be required to neatly house the circuit in their lamp. Lastly the students are required to recall and apply prior learning and knowledge of using engineering machinery and joining methods.


Project info

This project costs approximately £2.50 per student
I have attached the project work sheets
 
Remove these adsRemove these ads by Signing Up

Step 1: Creative Designing

Picture of Creative Designing
Nature is by far the best engineer, it creates the strongest structures, it makes the most beautiful designs, and its secrets have been the inspiration of many historic and iconic engineering achievements..........so we will use it to inspire our designs. Ask the students to bring in images to inspire their work.... some suggestions below.
  • Sliced Peppers
  • Sliced Oranges
  • Any tropical fruit....sliced
  • Architectural plants (see photos)
  • Any other natural item that has a structure or pattern e.g. wood grain
Rearrange, remove, overlap, repeat, twist, combine, modify.............these are the tools of creativity.... use them liberally.  

If you look at the 'Ideas' page you can see that the design does not look like the inspiration image, this does not matter, the images are there to inspire shapes......there is no right or wrong here......if you end up with a design......mission accomplished :)

Step 2: Card Model

Give the students pre cut card to the size of the materials provided

Blue card    = 155 x 110mm
Black card  = 155 x 110mm
White card  = 130 x 125mm

Using glue guns, tape etc...shape the card by hand to assemble a model of their design idea.

If any issues have been discovered from making the model make the required changes  and create the 3D final design. This allows the students to practice their isometric sketching and also allows them to apply their engineering knowledge to annotate the page. I encourage the students to use exploded and cross-sectional drawings to help communicate their ideas.

Step 3: 3D Final Design

Picture of 3D Final Design
Create a final design page, its important that the students add design detail of how the design is going to be made. This makes your life much easier as a teacher because it makes the students more independent in the workshop if they know how to make their design. Use the following to communicate the design details.
  • 3D sketches
  • Exploded views
  • Cross-sections
  • 2D drawings

Step 4: 3D CAD

Picture of 3D CAD
Assem4.JPG
Part1.JPG
We use SolidWorks but if you don't have any 3D software there are free CAD packages like Autodesk's 123D or google sketchup..... Both of these can produce excellent results and its free for schools to use.

You can produce 2D working drawings from the 3D virtual model......these are useful when making.

This is an ideal opportunity to teach the students about the exam theory on the use of CAD/CAM in industry. there are plenty of short vids on you tube you can show which clearly show automated machinery and mass production


Step 5: Lamp - Aluminium Sheet

Picture of Lamp - Aluminium Sheet
sheet.jpg
DSCN3028.JPG
DSCN3030.JPG
DSCN3032.JPG
  • Using precut aluminium 110 x 155 x 1.2mm
  • Using the dimensions developed from the 3D virtual modelling stage measure and mark out the aluminium sheet. 
  • Centre punch the hole positions
  • Drill the holes at Ø4mm
  • De burr the holes
  • Use 150grit abrasive paper to give the aluminium a 'brushed' look

Step 6: Lamp - Aluminium Sheet

Picture of Lamp - Aluminium Sheet
DSCN3034.JPG
  • Shape the aluminium using rollers for curves and folding bars for right angles
  • Use 150grit abrasive paper to remove any marks from rolling

Step 7: Acrylic

Picture of Acrylic
sheet.jpg
  • Using precut acrylic 110 x 155 x 3mm the students need to mark out their design, the sheet can be cut into a shape or used complete.
  • Leave the protective film on the acrylic as this prevents scratches
  • Mark out the hole centres on the acrylic sheet using a biro.

Step 8: Drilling the acrylic

Picture of Drilling the acrylic
  • Using a Ø5mm drill bit and a pillar drill create the two holes as per your marking out
  • Ensure goggles are worn, hair tied back and sleeves rolled up.
  • Drill slow and hold the acrylic down with a lot of pressure to avoid it shattering

Step 9: Sanding acrylic

Picture of Sanding acrylic
DSCN3038.JPG
  • Use a sanding board with 150grit paper on it to remove saw marks from all four edges
  • I also used wet&dry paper to polish the edge

Step 10: Thermo-forming the acrylic

Picture of Thermo-forming the acrylic
DSCN3040.JPG
DSCN3041.JPG
  • Set an oven to 170oC / If you do not have an oven you can use a heat gun / paint stripper
  • We use aluminium formers, other options are MDF or Pine
  • I have a number of aluminium strips 110 x 155mm for the students to create a former for their design by rolling and folding. I keep all the formers so they can be reused/modified for next years group.
  • REMOVE THE PROTECTIVE FILM!!!!
  • Put the acrylic and aluminium former in the oven and leave for 5mins.
  • Wearing heat proof gloves check to see if its ready by pushing the acrylic.....if its flexible, its ready
  • You sometimes have to use light pressure to hold the acrylic in place as it cools (See photo with two bits of wood)

Step 11: Lamp - Aluminium Tube

Picture of Lamp - Aluminium Tube
DSCN1425.JPG
  • Provide the Ø38mm ally tubes pre cut 20mm bigger than the ally sheet
  • Face both ends
  • Use a half round file to remove the burrs inside the tube

Step 12: Lamp - Aluminium Tube

Picture of Lamp - Aluminium Tube
DSCN1428.JPG
DSCN1429.JPG
DSCN1430.JPG
DSCN1433.JPG
  • Use a digital calliper to accurately measure the diameter of the tube (i know its standard Ø38mm tube but the kids do not)
  • Place the tube in a V-Block and place on a flat surface like a marking out plate
  • Using a height gauge to measure the overall height of the tube + block (this measurement = X)
  • Take the tube diameter measured in the last step and divide by two to get the radius (this = r)
  • Do the sum X-r = Centre of tube  (my sum was 48-12.5 = 35.5mm) set the height gauge to this height and scribe the centre line of the tube

Step 13: Aluminium Tube - Marking the hole centres

Picture of Aluminium Tube - Marking the hole centres
DSCN1442.JPG
DSCN3102.JPG
Measuring from the bottom of the tube, then drill, using a V-Block, centre punch and drill

Bolt Holes Ø4.2mm
The bottom hole will be 20mm
The top hole will be 90mm

LED Holes Ø5mm
The bottom hole will be 30mm
The top hole will be 80mm

Step 14:

Picture of
Using an M5 tap thread the four bolt holes

Step 15: Brushing the ally tube

Picture of Brushing the ally tube
DSCN3088.JPG
Using a lathe set to low speed, and 150 grit abrasive paper......sand the tube. The second picture shows the difference between sanded and not sanded.

Swap the ends round and sand the bit that was in the chuck.

Step 16: Aluminium Dial - Turning

Picture of Aluminium Dial - Turning
DSCN3079.JPG
dial.jpg
Parallel turn the top of the lamp on a metal lathe. Turn the cutting tool at a 45degree angle to cut the O-ring channel

Step 17: Aluminium Dial - Knurling

Picture of Aluminium Dial - Knurling
DSCN3083.JPG
DSCN3084.JPG
DSCN3085.JPG
  • Knurl the grip....use low speed...(approx 100RPM)
  • Part off the work

Step 18: Aluminium Spacers

Picture of Aluminium Spacers
DSCN3105.JPG
DSCN3106.JPG
DSCN3108.JPG
  • Use Ø8mm aluminium rod
  • Centre drill
  • Drill Ø5mm approx 30mm deep
  • Sand
  • Part off at 13mm
  • Repeat 3 more times

Step 19: Magnets

Picture of Magnets
DSCN3111.JPG
Use epoxy resin to stick on the Ø5x1mm neodymium magnets.

Step 20: Circuit

  • Using 4 super bright LED's, 360 ohm resistor, PP3 9v battery and the magnetic contact create the circuit as per the diagram.

Step 21: Insulate Wires

Picture of Insulate Wires
DSCN3099.JPG
Use insulation tape to protect any exposed wire, you must do a good job of this as the LED legs are particularly vulnerable to shorting on the ally tube if not covered properly.

Step 22: Install Circuit

Picture of Install Circuit
DSCN3115.JPG
  • Carefully add the circuit to the ally tube.....careful is the word if you force the circuit you are likely to snap wires
  • I use a plumbing pipe clip to hold the reed switch in place

Step 23: Asssembly

Picture of Asssembly
DSCN3117.JPG
  • Use M5x20mm bolts to assemble the aluminium and acrylic sides

Step 24: Students Work

Here are some examples of students practical and 3D CAD work, they made a version that is used to light up something on a desk e.g. Homework or keyboard etc... These examples are the first generation of this project and do not have reed switches.....just toggle switches. This years students will be including the reed switches.

The students work is graded on the following criteria
  • Quality of surface finish
  • Quality of fabrication and shaping of aluminium & acrylic
  • Creative thinking
  • Complexity of design
  • Technical detail on design page
JGUZMANO1 month ago

This is what I call an Engineering Project. Beautifully inspiring. Lucky young ones!

Thanks for sharing.

SIRJAMES093 years ago
And this is but a part of what is taught in the schools of England??

No wonder why American schools lag behind everyone else!
This is embarrassing to say the least to the American school system. *shakes head*

I think it's beyond awesome that things like this are taught over there...I mean, this goes WAAAAAAAAAY beyond my understanding or abilities, but the end result(in this case the light) is fantastic!!!

TY for sharing Sir! :)
jonnyd55 (author)  SIRJAMES093 years ago
Hay many thanks S09, dont be too hard on american schools! What I do at my school is VERY rare in the UK. Most schools technology projects over here are totally shamefull! its my life's mission to make the uk get back to power house of engineering and ingenuity it used to be 100 years ago.......or at least get it started on the road to recovery ;) Jonny
Here Here!
Definitely agree - I'm another UK based Technology teacher,and I only wish that my department were open to projects like this! I doubt I could convince those I teach alongside to do this, but I'll be making one in my own time for definite - it looks fab!
jonnyd55 (author)  lucylollipop3 years ago
Some of my ideas were accepted with no issues, other ideas I just did anyway because as I teacher I will always do what I think is right for my kids. If you want a tip....... When I first started as an nqt, and I knew my ideas would fall upon deaf ears, I thought of a superior project that uses the same materials as the existing work...... Then secretly started the project. So long as it follows the NC and costs the same, how can they complain......however....You need to be pretty confident your ideas will work though or you'll end up looking like a fool :)
well I personally think they have a great teacher! :)
I agree with SIRJAMES. They do have a great teacher.

It is rare, but there are many teachers in the US that are doing similarly awesome hands-on work with their students. Check out some of their submissions in the Teacher Contest. Instructables is trying to help bring this level of instruction to any teacher who wants to try it.
jonnyd55 (author)  wilgubeast3 years ago
Well....I am humbled, Thanks Jamie, Stu and wilgubeast for you lovely comments :) As for the awesome american teachers I defo agree with wilgubeast......there are some cool projects in the contest, my personal favourites are from stumitch and lakyama.............jolly good
Hey Jonny... thanks for standing up for us lil'ol' North Americans! mind you... i am Canadian so we are i suppose a pleasant "mix" of U.K. and U.S.A. call us UKSA's i guess. And i have to echo the feeling that amazing work is being done in tech classes all over the world. Check out all the entries just to clarify that point... nice job on the instructable!
-stu
Johenix3 years ago
One reason for the decline in American Industrial Arts Classes is the rise of the Liability Law Suite Lawyer and the subsequent rise in School Liability Insurance Rates.
Power tools? Too dangerous!!! Sheet metal? Too many sharp edges- some one might cut themselves!!! You get the idea. Too many GI Bill educated lawyers came out of the Viet Nam Vetrens.
I took a continuing ed class at a local high school a few years ago. Off to the side of the room was a complete foundry with gas forges, crucibles, sand tables, etc. Nothing had been used for a long time and upon inquiry, it was because of possible lawsuits that the school stopped offering shop classes. However, this was enabled by parents trying to shield their children from any adverse outcome. Now they have children that won't change a light bulb for fear of electrocution.

When I was in the 3rd grade (early 1970's) we had basic hand tools and a scrap wood bin in class. During free time anyone could build simple projects. By the 7th grade I was in metal shop and running a lathe as well as learning to gas weld. Tell most that now and you are looked at like you are crazy. Or, they wonder what was wrong with your parents for allowing you to do it. Kudos to jonnyd55 for finding a way to offer building projects to young minds.
That is very, very sad! I think around the globe children are being cotton-balled and not getting the chance to do exciting things for fear of repurcussions! Good point!
Beautiful work, clean lines and interesting! Who wouldn't like something like this on their desk - well done!
hertzgamma3 years ago
This is supreme! Well done!
derek_eide3 years ago
Excellent Instructable! My shop projects in High School were making a small flimsy tool box and a hammer and a table lamb from a syrup bottle. I wish I would have had a project as interesting as this. Please create more Instructables.
jonnyd55 (author)  derek_eide3 years ago
Hi, thanks for the nice comment :) unfortunately most of the projects in most of the UK schools are as you described....or much, much worse! As for more instructables.... watch this space :)
This is a really phenomenal, start-to-finish Instructable. I voted for you, primarily because I believe we need more instructional, hands-on teachers out there...I wish I had had you in high school.
jonnyd55 (author)  MercuryCrest3 years ago
Hi, thanks for your comment & vote :)
Wow. i don't think i've ever read such a comprehensive and thorough step-by-step instructible in my life! Pre-concept drawings, Cad models, and even in-situ videos!

Well done! !
jonnyd55 (author)  captain Jack3 years ago
Many thanks captain! pleased you enjoyed this ible :) ..... If you like what you see check out my other projects, or even better try to make one :)
tymann093 years ago
Stuff like this would've made high school fun for me and not depressing. I think if I had projects like this, I wouldn't be able to sleep because I'd be so excited to go to school the following day to work on it. I was fortunate enough that my school still had a very very small woodworking shop, no lathe though. It's amazing that such a small class showed me that woodworking was what I wanted to do for the rest of my life. It's a shame we can't get this kind of hands-on education back into schools like it once was.
I whole heartedly agree!!!
jonnyd55 (author)  tymann093 years ago
Hi, unfortunately your story is a common one in the UK, before i started at my school 5years ago our lathes were rarely used......now they are churning out cool stuff every day :)
thats awesome mate! looks like something straight out of an old scifi flick. i've been looking for some wiring projects and looks like a found one.

as a side note if you don't have the materials or tools for bending the metal. 1/8" ABS with a painted chrome/silver backing would be a great alternative to the aluminum.
jonnyd55 (author)  Towering Props3 years ago
Now you mention it....i can see what you mean....someting from lost in space perhaps :)

As for shaping the ally....if you dont have rollers... get a solid bar or pipe approx 2" in diameter and a leather mallet. Then bash the ally around the bar/pipe......you can get surprisingly good results from this :)
mmm yes that skipped my mind. ill have to make a couple of them using the plastic and then the ally with the different manufacturing methods and see how they come out. the dented ally shade would provide a "weathered" look to it which might be preferred by some.

ill defiantly show some pictures when i get around to it.
cheers.
jonnyd55 (author)  Towering Props3 years ago
Cool, defo upload the piccies of what you make :)
Johenix3 years ago
First, what is "KS4"?
I assume it is a part of a series of classes not taught in American schools.

We used to have up through the 1960's some pretty good Industrial Education "Shop" Classes.
Letter Press and Cold Type Printing, Woodworking, Wood Turning, Welding (popular with farm boys), Plastics, Electrical, etc.
Industrial Arts books from the 1930's to 1950 showed how to make electric buzzers, bells, telegraphs, earphones, microphones and crystal radios.

I actually learned to solder with a GAS heated SOLDERING COPPER in the seventh grade (age 12-14).

I spent grades 1-4 in a one room rural school where the teacher made certain that everyone knew how to sew on a button and make a button hole. (Lost arts??)

Have your class see how a WHITE PETE (plastic) bottle can act as a difuser for super bright LEDs. Energy shot drinks come in White PETE bottles. ( "/1\ PETE" recycle mark on the bottom.)

I had a wild idea for a TV series about six girls who try to build an electric car. I call it "Gadget Girls". It could break some stereotypes and get some girls into the shop classes.

jonnyd55 (author)  Johenix3 years ago
Hi, The easiest way to explain it is, KS4 is an age range of students.....goes like this

KS3 = 11 - 13 year olds
KS4 = 14-16 year olds
KS5 = 17-18 year olds
canucksgirl3 years ago
Very cool. I like your story board. Good Job. :)
jonnyd55 (author)  canucksgirl3 years ago
Hi, thanks for the comment :)