Design and development of a series of interior lighting for the Ford Motor Co.

1. Case Studies: Ford Corporate Map Dome

2. 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.
3D Rendering of the design release

3. Case Study: Ford Corporate Map Dome Lighting
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.

4. Case Study: Ford Corporate Map Dome Lighting
Concept Development Phase - Sketches
Magnifying Optics
On/Off Switching
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.

5. Case Study: Ford Corporate Map Dome Lighting
Concept Refinement Phase
Photoshop Illustrations - various form study concepts
On/Off Switching
Two shot lens and bezel
manufacturing was considered for
part reduction.
Magnifying Optics
Dome Lighting

6. Case Study: Ford Corporate Map Dome Lighting
Concept Refinement Phase
Photoshop Illustration – BOM
Study
Reflectors
Insert molded back plate
Cartridge bulbs
Rocker switch caps
Two shot molded all lens design

7. Case Study: Ford Corporate Map Dome Lighting
Concept Refinement Phase - 3D Surfacing and Rendering
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).

8. Case Study: Ford Corporate Map Dome Lighting
Concept Refinement Phase - 3D Models
CNC Prove-out model
of Class A surface
Approved Clay
model surface
done by clay
modelers
Casting from
Clay model for
surface review
at Ford

9. 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

10. Case Study: Ford Corporate Map Dome Lighting
Finalization – Production Release
Production Release – still used today in several Ford
vehicles

11. Case Study: Ford Corporate Map Dome Lighting
Finalization – In Vehicle Photos
F-150
Edge
Flex
Current Ford Vehicles
that the Lamp is used in

12. 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

13. Contact Information
Bazza Design LLC
Barry Hutzel - Principal
2058 Breeze Drive Holland MI 49424
barry.hutzel@bazzadesign.com
bazzadesign.com
616 335 0219