These ”E-Bulb” prototypes were designed and fabricated to showcase their unique features and patented technology.  A quantity of 30 identical bulbs were built in order to be sent off to both UL and Energy Star testing facilities.  A variety of processes and programs were used in the construction including Laser Cutting and CNC machining using both Solidworks and MasterCAM for precise results that could be duplicated as many times as necessary.

Design features included brightness icons to distinguish between the two power level settings, which allow the user to save energy if there is not a need for full brightness.  These icons and selector switch are displayed on a flat plane “cut” into the unit.  This design element also helps the user identify how to connect the base section to the bulb, another unique feature.  By aligning the brass pins of the bulb into the keyhole connection located on the base portion, the light bulb becomes a single seamless unit.

An abundance of heat, generated by the halogen bulb, was taken into consideration by applying a 1.5mm layer of clear silicone to the inside of the glass housing to help dissipate the heat.  A highly heat resistant plastic called Acetal was also utilized in the bulb housing.