This phase defines the product's soul and specifications.

1. Concept & Brief:

   • Inspiration & Ideation: Mood boards, market research, and trend analysis.

   • Design Brief: Defines the target market, price point, key aesthetics, and functional requirements (e.g., indoor/outdoor use, dimmability).

2. Design & Engineering:

   • Sketches & Renderings: Initial hand-drawn or digital (CAD) sketches explore form and proportion.

   • 3D Modeling & Visualization: Detailed CAD models are created. Photorealistic renderings show the fixture in virtual spaces.

   • Technical Design & DFM (Design for Manufacturing): Engineers ensure the design can be produced efficiently, cost-effectively, and safely. They select materials, specify components (sockets, drivers, heat sinks), and plan assembly.

3. Prototyping:

   • Functional Prototype ("Looks-like, works-like"): A full-scale model is built, often using techniques like 3D printing, hand-forming, or machining. This prototype tests aesthetics, proportions, and basic function.

   • Testing & Iteration: The prototype undergoes user testing, photometric testing (light distribution, glare), thermal management checks, and safety reviews. The design is refined based on feedback.

The design is prepared for the factory floor.

4. Final Specifications & BOM:

   • A definitive Bill of Materials (BOM) is created, listing every single component (fasteners, wiring, diffusers, LED modules, packaging).

   • Final technical drawings, tolerances, and assembly instructions are locked in.

5. Tooling & Sample Making:

   • Tooling Creation: Investment is made in permanent molds for injection-molded parts, dies for metal stamping, or jigs for assembly. This is a major cost and time factor.

   • Pre-Production Samples: The factory produces the first samples using the actual production tools and materials. These are rigorously checked against the approved prototype for quality, finish, and performance.

The physical products are built at scale.

6. Component Sourcing & QC:

   • All raw materials (metal, glass, plastic) and electronic components (LED chips, drivers) are sourced, often from specialized suppliers.

   • Incoming Quality Control (IQC): All received parts are inspected before entering the production line.

7. Assembly Line Production:

   • The process follows a detailed assembly line workflow:

     • Fabrication: Cutting, bending, stamping, welding of metal parts; blowing/cutting of glass.

     • Surface Treatment: Polishing, painting, powder-coating, anodizing, plating.

     • Sub-Assembly: Wiring harnesses, installing sockets, attaching diffusers.

     • Final Assembly: Putting all sub-assemblies together, installing the light engine (LED module + driver).

     • Aging & Testing: Fixtures are often burned-in (powered on for hours) to catch early failures. They undergo electrical safety, photometric, and function tests.

8. Final Quality Control & Packaging:

   • Finished products are inspected for cosmetic flaws and functional issues.

   • They are packaged according to specifications, ensuring protection for shipping and retail presentation.

The product reaches the end-user.

9. Logistics & Distribution:

   • Products are shipped from the factory to regional warehouses, distributors, or directly to retailers.

10. Installation & Support:

    • For complex architectural or custom lighting, this involves commissioning by a lighting designer or electrician—aiming, focusing, and programming control systems.

    • The process concludes with after-sales support, warranties, and potentially future maintenance.