bazza design case study ford corporate map dome lamp
DESCRIPTION
Design and development of a series of interior lighting for the Ford Motor Co.TRANSCRIPT
Case StudiesCase Studies: Ford Corporate Map Dome: Ford Corporate Map Dome
3D Rendering of the design release
Case Study: Ford Corporate Map Dome Lighting
Project Lead
Program Management
Industrial Design
Working Prototypes
3D Release
Production Launch
Project Brief:Donnelly Corporation was asked to create a series of lighting products for the Ford Motor Company that reduced Ford’s lighting part numbers from fifty different interior overhead lighting products down to seven part numbers for all Ford vehicles. The map dome lamp shown here is one of the three that I helped design for Donnelly. Donnelly produced the lights for Ford vehicles that needed map reading and dome light features for the interior of their vehicles. The designs was cost effective (minimal parts), all lens design (no color match needed), and exceeded the light output specifications for Ford vehicles. The lamps are still used in Ford cars, trucks, SUV’s and crossover’s today.
Research Phase - Trend and Theme Boards
The boards were created to set the tone for the designs to come. They took in account Ford’s product line, relevant competitive products, concept vehicle directions, fashion, and related consumer products that where highly styled and mechanically based in design.
Case Study: Ford Corporate Map Dome Lighting
Concept Development Phase - Sketches
On/Off Switching
Magnifying Optics
Edgy forms combined with soft curves became a direction to take. This kind of styling was the direction that Ford was taking with its vehicles at the time.
Case Study: Ford Corporate Map Dome Lighting
Photoshop Illustrations - various form study concepts
Concept Refinement PhaseOn/Off Switching
Magnifying Optics
Dome Lighting
Two shot lens and bezel manufacturing was considered for part reduction.
Case Study: Ford Corporate Map Dome Lighting
Concept Refinement PhasePhotoshop Illustration – BOM Study
Reflectors Insert molded back plate
Cartridge bulbsRocker switch caps
Two shot molded all lens design
Case Study: Ford Corporate Map Dome Lighting
An “all lens” appearance (for cost reasons) was established. It became critical to add details into the 2nd surface of the design to enhance light output in critical areas and reduce see-through in non-optical areas. Coach joint details were strategically added to the look for styling and mechanical reasons (they hid attachment details, to the back plate, on the 2nd surface of the lens).
Concept Refinement Phase - 3D Surfacing and Rendering
Case Study: Ford Corporate Map Dome Lighting
Concept Refinement Phase - 3D Models
Approved Clay model surface done by clay modelers
Casting from Clay model for surface review at Ford
CNC Prove-out model of Class A surface
Case Study: Ford Corporate Map Dome Lighting
Complete 3D Modeling
Full set of models,
molds, and working
prototypes for the
complete program of 3
styles of lamps
Case Study: Ford Corporate Map Dome Lighting
Finalization – Production Release
Production Release – still used today in several Ford vehicles
Case Study: Ford Corporate Map Dome Lighting
Finalization – In Vehicle Photos
Current Ford Vehicles that the Lamp is used in
F-150
Edge
Flex
Case Study: Ford Corporate Map Dome Lighting
Final 3D for two additional designs released for production as a family of lights
Header Map Dome Lamp with Moon Roof Switch Cargo Dome lamp with slider on/off/courtesy function switch
Case Study: Ford Corporate Map Dome Lighting
Contact Information
Bazza Design LLC
Barry Hutzel - Principal
2058 Breeze Drive Holland MI 49424
bazzadesign.com
616 335 0219