Waffle Cone

|| Design Process ||

iamRapid Engineering Design Services specializes in advanced mechanical and electromechanical CAD design, providing expert support for projects of any scale. Our experienced design team guides you in choosing the right design approach, ensuring high-quality CAD services at the best affordable prices.

Understanding customer requirements is our top priority in product design and development. We begin by gathering all necessary data to initiate the process, ensuring a strong foundation for success. Our team leverages their expertise to offer valuable insights and recommendations, helping customers refine their products and make informed decisions.

Through brainstorming and ideation sessions, our research team evaluates all potential concepts, conducts market and feasibility studies, and compiles a comprehensive report. This document is then shared with the customer, allowing them to select the best idea to move forward into the concept development phase.

Once the concept is finalized, it is meticulously designed using CAD software, undergoes simulations for testing, and is then optimized for manufacturability. After the customer approves the CAD design, we proceed to production using the chosen additive manufacturing method. Following production, we perform necessary post-processing to ensure quality and precision before delivering the final product right to the customer’s doorstep.

At iamRapid, we are committed to turning ideas into innovative, manufacturable solutions, ensuring efficiency and excellence at every stage of the design process.

The ideation process for the waffle cone decorative bulb housing began with a clear understanding of the client’s requirements. Two key design parameters were established: first, the waffle cone housing needed to have an overlapping structure to replicate the authentic texture and appearance of a real waffle cone; second, the surface grid pattern had to feature equally spaced squares for a clean, polished look.

With these design goals in mind, the next step was to source and select the appropriate light components — the bulb and bulb holder. Once acquired, precise measurements of both elements were taken, including the dimensions of the bulb’s diameter, height, and the wire opening on the holder. These measurements were essential for ensuring a snug fit and seamless integration of the lighting elements within the decorative housing.

This foundational ideation and research set the stage for the CAD modeling phase, where the vision of the waffle cone light fixture would start taking a tangible shape.

CAD Modelling

The CAD modeling phase was one of the most challenging yet rewarding parts of the project. The entire design was developed using SolidWorks, a parametric CAD software with limited capabilities in advanced surface modeling. The complex nature of the overlapping cone structure posed significant challenges in applying the evenly spaced grid pattern across the surface.

Creating the cone’s realistic, layered effect required a deep understanding of parametric modeling techniques and creative problem-solving. Despite the software’s limitations, we experimented with multiple surface modeling approaches, iterated over numerous design solutions, and invested several hours fine-tuning the design.

One of the key breakthroughs came from optimizing the grid layout process, ensuring it adapted seamlessly over the curved and overlapping surface without distortion. The final CAD model successfully captured the essence of a real waffle cone with an intricate, precise grid pattern and a realistic overlapping structure, ready for 3D printing and eventual production.

Design for Additive Manufacturing (DfAM)

The design for additive manufacturing (DfAM) phase focused on optimizing the waffle cone bulb housing for efficient and high-quality 3D printing. Several key considerations guided this process:

• Designing the main module to be printed without supports, ensuring a clean finish and reducing post-processing time.
• Minimizing material usage while maintaining structural integrity for a balance between strength and efficiency.
• Optimizing part orientation for better print quality and dimensional accuracy.
• Accounting for heat dissipation of the bulb: To manage this, we opted for LED bulbs that emit significantly less heat than halogen bulbs while delivering a similar warm lighting effect. Given PLA’s glass transition temperature of around 60°C and its melting point between 170 °C and 180°C, we used high-temperature PLA to further ensure safety and durability when combined with the low-heat LED bulb.

By adhering to these principles, we ensured that the final product was not only visually accurate but also manufacturable at scale with minimal waste and maximum consistency.

Post Processing & Assembly

Thanks to the support-free design, the post-processing phase was kept minimal. After printing, the only required steps were removing the brim and light sanding to achieve a smooth, even surface. As the cones were printed in white PLA, the painting was essential to match an actual waffle cone's warm, golden-brown hue. This approach allowed us to achieve an accurate, realistic color and texture.

Assembly was straightforward and efficient. It involved connecting the wire to the bulb holder, carefully inserting the bulb holder into the 3D-printed cone housing, and finally attaching the light bulb. This simple process ensured the decorative fixture was easy to install while maintaining a secure and stable fit for long-term use.

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