Patented Ball Joint
Trapeze moves unlike any other task light, 360° in every axis. The ball joint is at the heart of it all, here are just a few thinking sketches that helped me visualize how the joint could be made.
I built a simplified model of the joint in solidworks- this served as a "functional sketch", allowing me to prove that the concept of the joint is feasable. Later in the process I returned to this model to dial in the maximum possible travel for the joint.
This model, made with aluminum tubing, FDM parts, lead shot, and foamcore, gave me a chance to test the action and range of motion, leading to many refinements.
The first model showed us that the arm coming from the base needed to be angled, and I designed a testing base that would help us find the right angle. The more developed form in this model helped us make decisions about the appearance.
Machined Aluminum Models
One visit to Shenzhen gave me a few weeks to work directly with engineers and machinists to explore different construction methods. We made giant leaps forward there through trial, error, and brainstorming.
The original concept called for a spherical base, which would be heavy enough to hold trapeze in place. Once we started testing with models, I realized that we needed area, not weight- and immediately started developing a thin, light base.
While I was working with mechanical engineers to fine tune the moving parts, a team of electrical engineers was prototyping the thin plastic shell and innovative light engine for the head. These were the first models to put it all together.