2. Ideation
Market Research
- Do It Yourself (DIY) solutions with paper, string, ping
pong balls and paper cups
- Sets with single design on each light
- If a light burns out, the whole string is then
compromised
- Able to use the amount of Christmas lights already
owned
- Residence Hall Rooms, Patios, Children’s Rooms,
Holiday lights
3. Ideation
Sketches
- Early sketches tried to bring out the simplicity of the
Christmas Light
- Easy to re-create shapes
- Home Decor
- Pop Culture
6. Development
Prototyping
- Printed parts using Fused Depostion Modeling
(FDM) and Stereolithography (SLA)
- 10-15% infill and no more than 2 shells to allow
light to shine though
- Can be printed in Polylatic Acid (PLA),
Acrylonitrile Butadiene Styrene (ABS), or a
photopolymer resin
- Temputure of lights do not reach melting point of
any of the above materials
FDM Objet SLA
7. Development
Prototyping
- Printed parts using Fused Depostion Modeling
(FDM) and Stereolithography (SLA)
- 10-15% infill and no more than 2 shells to allow
light to shine though
- Can be printed in Polylatic Acid (PLA),
Acrylonitrile Butadiene Styrene (ABS), or a
photopolymer resin
- Temputure of lights do not reach melting point of
any of the above materials
FDM Objet SLA
8. Development
Challenges and Solutions
- Modifying clip for light to hang
- Finding best priting orientation for surface finish
- Post-process FDM with Acetone
- Letters
9. Production
Finances
Price Study for FDM Part
Price for material on one piece:
Transparent PLA: $0.17
Energy cost to print on Makerbot: ~$0.03 per hour
Selling cost for one piece: $0.20
Sell at price: $0.75
Sets:
Letters (A-Z, 26)- $19
Letters (Happy Birthday)- $10
Set of 35 (mix and match)- $25
Set of 50 (mix and match)- $40
In Progress Print on MakerGear
FDM Printer