Module 3 Activity Research

Weekly Activity Template

Tim Ziaziulchyk

Project 3

Module 3

In module 3 I brought my RGB Lamp project from a concept and early breadboard test into a fully functional prototype. This phase focused on testing, troubleshooting, and refining both the physical and electronic systems. I measured every component to model accurate housings, designed and 3D printed multiple iterations of the lampshade and casing, and refined tolerances until everything fit together securely. I also spent a significant amount of time soldering and rewiring the internal electronics, testing power delivery, and resolving issues with short circuits and broken LED pads.

Research & Planning

One of my favourite lamp designs that I came across while watching videos on YouTube. I absolutely love the overall form of the lampshade and is something I will experiment with.

When I started looking for lamp inspirations, one of the very first lamp brands that stood out to me is Leora. They make 3D printed art lamps, which are beautiful, as they are so organic and disperse light in unique ways, which are things I'd love to explore further.

A visual render of how my lamp may look like, which I created with ChatGPT back in P2.

3D Modelling & Printing

Notebook page of the measurements of some of the components that I've done, using digital callipers.

First lampshade that I modelled in Fusion360, test printed in translucent PETG, and tested against a light source for light dispersion.

Second lampshade that I modelled in Fusion360, test printed in white PLA, and tested against a light source for light dispersion.

Fusion360 sketch for the top lid of the lamp, using the somewhat accurate dimensions.

Final 3D modelled top lid, with cutouts for rotary encoders and LED wires, as well as channels for LED rings and the lampshade.

3D modelled outer casing without any slots/holders for components.

Slot/holder for the ESP32 with channels for the pins to go into and a cutout for the USB-C port.

Cylindrical slot/holder for the capacitor.

Dovetail-style slot/holder for the rotary encoders.

Figuring out the placement for the rotary encoder slots/holders by using dimensionally accurate 3D models of my rotary encoders.

Added cutouts for press-fit rocker switch and USB Type-C port for power.

Final 3D modelled lamp outer casing with all the slots/holders for the components, as well as the slots for cable management.

Photo of most of the 3D printed test parts that I made for testing part tolerances and dimensional accuracy for the 'perfect' fit.

Wiring & Soldering

Cleaning up the rough spots on most of the PCB's to ensure proper fitting of the components, before soldering everything.

First half of the soldering process, soldering the rocker switch, Type-C port, capacitor, one of the rotary encoders, and the ESP32 to the common PWR and GND 'rails'.

Last part of the soldering process with almost all the components being soldered together.

The biggest mistake that I made throughout this whole project - soldering off one of the contact pads from one of my NeoPixel LED ring, 'killing' the ring. Despite ordering a replacement ring, I still could not make it work as the replacement was ever so slightly too big to fit into my lamp.

Project 3

Project 3 Final Prototype

For P3 I turned my RGB Lamp from a proof-of-concept into a working physical prototype. I focused on testing and refining both the 3D-printed housing and the electronics: modelling and reprinting parts for better fit, soldering and rewiring the NeoPixel rings, and troubleshooting issues like shorts and broken pads. Even though I couldn’t get all three rings running perfectly at the same time, I successfully demonstrated the core interaction of my lamp, which is rotating each shade to mix light and colour. This project confirmed that my design is buildable in the real world and gave me a much clearer idea of how to improve the next iteration.