I led the team at Philips that designed and built the eWBurst PowerCore luminaire. One of the reasons the project was successful was because I included downstream partners (manufacturing and quality) in the concept brainstorming sessions at the inception of the program. The initial team included an industrial designer, a manufacturing/quality engineer, and electrical engineer, a mechanical engineering co-op, mechanical engineer and me. The concept development process was highly collaborative. We created many design option, chose materials and manufacturing methods, and selected the final concept within 2 weeks.
The fixture was made from cast aluminum. The LED board and power supply were cooled with natural convection. The housing had to keep water out. Multiple mounting schemes and light hoods were also designed to give light designers options for using the product. The product won the Next Generation Luminaire Best in Class Award.
Shown below are 3D printed concepts demonstrating the different mounting strategies and light hood designs.