JOY EXISTS IN THE EXPEIRENCE OF ASSEMBLING A PRODUCT THE FLAT PACK LAMP

PROCCESS JOURNAL KAZIM KHIMJI Z3411891

THE FLAT LAMP

JOY OF GIFTING?

The user of a product fosters an emotional connection with the product. Joy exists in the experience of using a product. By adding the element of assembly to the use of the product, the flat lamp builds an emotional connection with the receiver

 IKEA: AN INSPIRATION

Flat pack refers to a form of products that is purchased in multiple pieces and requires the user to assemble them. Most flat packs are packed in a box with instructions on how to assemble the product. Flat pack works to reduce delivery costs by minimizing the volume of the package. This assures that more of the product can be shipped at a one time during transport. Both consumer and manufacturer benefit from this in the form of lower production costs (manufacturer) and lower prices (consumer). A popular example of flat pack products is Ikeas furniture. Ikea from Sweden manufactures flat pack furniture that is low cost and assembled by the user. It is known widely for its use of flat pack. See image to right for an example of one of the instruction sheets provided with a flat pack product.
Source: http://www.translationblog.co.uk/wpcontent/uploads/2010/03/Lauren-pic12.jpg

Kurk
EXISTING FLAT PACK DESIGNS

Kurk is a flat pack lamp that can be assembled without any screws or glue. The design focuses on the lifecycle of the product. Each component can be recycled or reused when the product is no longer needed. Flat Pack ZETA Lamp The Z like shape of the ZETA lamp is what gives it its name. It is made from interlocking pieces of plywood. It Is made from a single sheet of 38cm x 38cm plywood, and laser cut. Its light weight and small product package makes shipping in expensive. The user is left with the joy of assembling the product in his/her own. It is made from cork, which has an interesting visual property. Cork is sustainable and is also environmentally friendly. The downside of this design is that the height or the angle of the lamp shed cannot be adjusted. Furthermore, it uses a halogen light bulb, which is rather inefficient.

 MATERIALS SUITABLE FOR FLAT PACK

It is key to select materials that create a balance between sustainability and function to create a product that is environmentally friendly. Here are a few options:
Bamboo Grown in most Asian countries, it has a fast rate of growth. It requires less fertilizers and pesticides, making it a renewable material. This material is more durable than some hardwoods. It has a high strength to weight ratio. It can be cut and laminated into sheets and planks. The bamboo must be treated. Without treatment, the bamboo will split and will only last 3 years. Using chemical treatment is an unsustainable method of strengthening bamboo. A better method would be to bake the bamboo over an open fire as this works to dry and strengthen it. Cork Cork is considered a sustainable material. It is both biodegradable and renewable. Cork is obtained from the peel of the bark of the cork oak tree. The tree is allowed to regenerate. Cork is an impermeable material, which allows for it to breath. This is ideal for lighting as the light source may create heat. Cork has an interesting texture and in my opinion can add to the appeal of the product. Recycled Cardboard Recycled cardboard is manufactured from 100% post-consumer recycled paper pulp. Recycled material means that we extract less from the environment and utilize what we have already sued. Recycled cardboard can be manufactured into sheets of different grades, and perforated to allow for folding. Recycled cardboard is considered durable due to it interior fluting. It is customizable and insulating.

LIGHTING TECHNOLOGY

Traditional incandescent Electric current heats up the bulbs tungsten filament until it glows. This bulb is characterized by short life spans, high heat production and energy consumption. Compact fluorescent Excited gas in a fluorescent tube emits ultra violet photons to emit visible light on the bulbs coating. The lifespan of this bulb is fairly long and the energy consumption is fairly low. However, LED bulbs are also a viable option for lighting. LED LEDs produced the lowest heat, are most efficient and have the longest life span. This is a more suitable lighting option and will extend the lifecycle of the product by making it last longer in use. LEDs will not burn materials like cardboard or bamboo.

CONCEPT EXPLORATION

CONCEPT EXPLORATION

CONCEPT EXPLORATION

CONCEPT EXPLORATION
A few of the bamboo faces are colored. Soy Ink has been used to apply color as it is not petroleum based ink.

 OKALA ECODESIGN STRATEGY GUIDE

Criterion that apply: Avoid Materials that deplete natural resources The Flat Lamp is made predominantly from bamboo (90%), Components include the lamps interlocking legs and shed. Bamboo is considered renewable due to its rapid growth. Bamboo can reach a mature height of 75ft within two months. Design to reduce material impacts By using bamboo; the impact of material consumption on the environment by the manufacture of this product is reduced. This is because bamboo is renewable. Soy Ink covers 3 sides of the bamboo components that make the lamp. Soy Ink is more environmentally friendly as it is made from soybeans as opposed to petroleum-based inks. The soy ink adds to aesthetic appeal of the product by providing color. Minimize energy use in production Through flat pack, there is no requirement for the product to be assembled. The manufacturer saves the cost of assembly and the user completes assembly. This is done through the concept of flat pack inspired by Ikea. Reduce packaging volume Through flat pack, the volume of the package is minimized. This will also lead to reduce transport costs, and the ability to ship more units/pieces per pallet. Reduce energy consumption during use Energy consumption is reduced through the use of LED technology. The LED creates less heat and is therefore more efficient.

 COMPUTER AIDED MANUFACTURE (CAM)

Computer aided manufacture is how most flat pack furniture is made. Although the cost of setting up this technology is high, the manufacturer gains benefits in the long run. Computer aided manufacture, in the case of The Flat Lamp is ideal. This is because CAM is very accurate and precise when it comes to cutting sheets of wood like bamboo. Precision is important because the components of the Flat Lamp interlock. Procedure for The Flat Lamp: The template for the bamboo components are imported into CAM software where a CNC router then outputs a series of controls that cut the sheet into the desired shape. This is done in the following stages: -Roughing -Semi finishing -Finishing -Contour milling. Subsequent work is done by hand. This includes sanding, drilling any holes for the passage of wires, and the application of any color. After the components are manufactured, they are packaged as flat pack items. The packaging volume is reduced through a slim, flat box.

CAD MODELLING

APPEARANCE MODEL

APPEARANCE MODEL

APPEARANCE MODEL

HERO SHOT