When developing a new lamp design, le processing of lamp prototypes is a critical link that directly determines whether the final product meets design expectations. A well-executed prototype not only verifies functionality and aesthetics but also lays the groundwork for mass production. This article breaks down the core steps, considérations clés, and solutions to common challenges in lamp prototype processing, helping you avoid pitfalls and achieve optimal results.
1. Sélection des matériaux: The Foundation of Prototype Quality
Choosing the right material is the first step to success—different materials vary in transparency, résistance à la chaleur, et la transformation, directly impacting the prototype’s performance and appearance.
| Type de matériau | Caractéristiques clés | Ideal Lamp Applications |
| Plastique abs | Facile à machine, Bonne résistance à l'impact, dyeable | Desk lamps, floor lamps (non-heat-intensive parts) |
| Acrylique | Transparence élevée, excellent gloss, résistance modérée à la chaleur | Lampshades, light diffusers |
| Plastique PC | Résistance à la chaleur élevée, ignifuge, fort | LED downlights, high-temperature lamp housings |
| Alliage en aluminium | Léger, bonne conductivité thermique, forte résistance | LED lamp heat sinks, cadres structurels |
| Résine | Excellent for complex shapes, customizable transparency | Artistic lamps, prototypes with intricate details |
Question clé: How to prioritize material properties?
For light-transmitting parts (Par exemple, coiffures), prioriser transparence et brillant (Par exemple, acrylique). For heat-generating parts (Par exemple, LED bases), prioriser conductivité thermique (Par exemple, alliage en aluminium).
2. Technologie de traitement: Matching Methods to Needs
The choice of processing technology depends on prototype complexity, taille de lot, et les exigences de précision. Below is a comparison of the most common methods:
| Technologie | Avantages | Désavantage | Mieux pour |
| 3D Impression | Fast for complex shapes, low cost for small batches | Surface may have layering, Options de matériaux limités | Intricate prototypes (Par exemple, artistic lamp bases), petits lots (<10 unités) |
| Usinage CNC | Haute précision (± 0,01 mm), surface lisse, suitable for hard materials | Slow for complex designs, high cost for small batches | Pièces de haute précision (Par exemple, metal heat sinks), gros lots (>20 unités) |
| Moulage en silicone | Low cost for multiple copies, qualité constante | Requires a master prototype (made via 3D printing/CNC) | Duplicating prototypes (Par exemple, 50+ identical lampshades) |
| Fabrication à la main | Flexible for unique details, suitable for special materials | Prend du temps, qualité incohérente | Custom touches (Par exemple, hand-sanded resin details, small-scale art lamps) |
Pour la pointe: For complex components, combine technologies—e.g., use 3D printing to create a master prototype, then use silicone molding to produce multiple copies. This balances speed and cost.
3. Conception structurelle: Avoiding Common Failures
Poor structural design can lead to assembly issues, déformation, or functional failures. Focus on these three areas:
3.1 Compatibilité d'assemblage
Design with assembly methods in mind to ensure components fit securely and easily. Common assembly methods include:
- Snaps: Ideal for plastic parts; ensure snaps have enough flexibility to avoid breaking.
- Vis: Suitable for metal/plastic connections; use standard sizes (Par exemple, M3, M4) for easy sourcing.
- Glue: Meilleur pour les pièces sans charge (Par exemple, lampshade attachments); choose heat-resistant glue for LED lamps.
Éviter: Tight fits (cause assembly difficulty) or loose fits (lead to instability).
3.2 Thin-Wall Treatment
Lampshades and light diffusers often use thin-wall structures. To prevent deformation or cracking:
- Maintain épaisseur de paroi uniforme (1.5–3mm pour le plastique; 0.8–2mm for aluminum).
- Ajouter stiffeners (Par exemple, small ribs) to ultra-thin sections (≤1 mm) for extra support.
3.3 Thermal Design (Critical for LED Lamps)
LED lamps generate heat, which can warp prototypes or reduce lifespan. Les solutions incluent:
- Integrate trous de dissipation de chaleur (diamètre: 2–5 mm) in the lamp housing.
- Utiliser metal bases (alliage en aluminium) to transfer heat away from the LED chip.
- Avoid covering heat-generating parts with thick plastic (blocks heat escape).
4. Traitement de surface: Amélioration de l'esthétique et de la durabilité
Surface treatment improves the prototype’s appearance and protects it from wear. Vous trouverez ci-dessous les méthodes les plus efficaces:
| Méthode de traitement | But | Considérations clés |
| Ponçage & Polissage | Retirer les marques d'usinage (Par exemple, CNC knife marks, 3D print layers) | Use 400–2000 grit sandpaper (grossier à fin); polish acrylic to a high gloss with a buffing wheel. |
| Pulvérisation | Add color or texture (mat, brillant, métallique) | Use UV-resistant paint for outdoor lamps; ensure no bubbles or flow marks. |
| Électroplaste | Create a metallic finish (chrome, nickel) | Suitable for metal parts; avoid plating on plastic (low adhesion). |
| Impression d'écran en soie | Add text or patterns (Par exemple, Logos de marque) | Use durable inks; test for wear resistance (Par exemple, rub with a cloth). |
5. Assemblée & Essai: Verifying Prototype Reliability
Skipping testing can lead to costly mistakes in mass production. Follow this step-by-step process:
Étape 1: Validation fonctionnelle
Test core lamp functions to ensure usability:
- Éclairage: Check if the light turns on/off smoothly; verify brightness (Par exemple, 500–800 lumens for desk lamps).
- Switches/Dimming: Test switch responsiveness and dimming range (le cas échéant).
- Dissipation thermique: Run the lamp for 2–4 hours; measure surface temperature (should not exceed 60°C for touchable parts).
Étape 2: Inspection visuelle
Compare the prototype to design requirements:
- Vérifier cohérence des couleurs (use a Pantone color chart for reference).
- Inspecter les défauts: rayures, blemishes, or uneven gaps (gaps should be <0.5MM).
- Vérifier transparence (pour pièces acryliques: ensure no cloudiness).
Étape 3: Stabilité structurelle
Simulate real-world use to test durability:
- Load-Bearing: Place a small weight (Par exemple, 500g) on the lamp base (should not tip over).
- Résistance aux chocs: Drop the prototype from 30cm (no cracks or loose parts).
- Durabilité: Open/close the lamp shade 50 fois (no damage to hinges).
6. Yigu Technology’s Perspective on Lamp Prototype Processing
À la technologie Yigu, we believe that precision and adaptability are key to successful lamp prototype processing. Many clients initially prioritize speed over material selection, leading to rework (Par exemple, using low-heat-resistance plastic for LED lamps). Our approach is to first align materials with functional needs—e.g., recommending PC plastic for high-temperature LED parts or aluminum alloy for heat sinks—then optimize processes to balance speed and cost. We also emphasize data management: saving 3D models, paramètres d'usinage, and test reports ensures consistency if modifications or mass production are needed. By combining technical expertise with client feedback, we help turn lamp designs into reliable prototypes that accelerate product launch.
7. FAQ: Solving Common Lamp Prototype Issues
T1: My prototype has dimensional deviations—what causes this?
A1: Dimensional deviations usually stem from two issues: insufficient processing accuracy (Par exemple, CNC toolpath errors) ou rétrécissement des matériaux (common with plastic). Solutions: Optimize CNC toolpaths (use high-precision tools) and reserve 1–2% shrinkage allowance for plastic materials (Par exemple, ABS shrinks ~1.5%).
T2: The lamp shade has poor light transmittance—how to fix it?
A2: Poor transmittance is often due to wrong material selection (Par exemple, using opaque plastic instead of acrylic) ou inadequate polishing (machining marks block light). Correctifs: Switch to high-transparency acrylic and polish the surface with 1500–2000 grit sandpaper followed by a buffing wheel.
T3: Assembled parts are loose—what’s the solution?
A3: Loose parts usually result from unreasonable design (Par exemple, snaps that are too thin) ou processing errors (Par exemple, CNC parts are too small). Solutions: Ajuster le design (thicken snaps by 0.2–0.3mm) or improve machining accuracy (use a CNC machine with ±0.005mm precision).