Lightbulb Teardown

Parts Overview

  1. Outer Shade
    Material: Polycarbonate plastic
    Function: Acts as a diffuser for the LEDs (3.)
    Manufacturing Technique: Injection molding
  2. Central Housing
    Material: Polybutylene terephthalate
    Function: Holds all internal components (3., 5., 6., 7., 8., 9.) and provides insulation and structural support between the hot electronics and the metal base (4.)
    Manufacturing Technique: Injection molding
  3. Flat LED Panel
    Material:
    Substrate: Aluminum metal-core printed circuit board
    LEDs: Semiconductor chips (gallium nitride, GaN) mounted in epoxy or silicone encapsulants
    Function:
    Substrate: Spreads heat away from the LEDs to maintain efficiency and lifespan
    LEDs: Generate light
    Manufacturing Technique: Metal-core PCB fabrication, surface-mount technology (SMT), reflow soldering
  4. Metal Screw Base
    Material: Aluminum
    Function: The threaded part connects mechanically to the socket’s neutral line, and the bottom tip contact connects electrically to the live line.
    Manufacturing Technique: Cold heading, thread rolling, stamping, nickel plating
  5. Circuit Board (Labeled E64353)
    Material: FR-4 fiberglass PCB with copper traces
    Function: Holds all the electronic components (6., 7., 8.) in place and provides electrical pathways through the copper traces that connect components together
    Manufacturing Technique: Laminating, copper cladding, photolithography and etching, solder mask application, silkscreen printing
  6. Inductor
    Material: Copper wire, ferrite core, plastic insulation
    Function: Filters electrical noise, smooths current, and improves efficiency
    Manufacturing Technique: Wire drawing, encapsulation
  7. Bridge Rectifier
    Material: Silicon semiconductor encased in epoxy resin
    Function: Converts high-voltage AC (120/230 V) into low-voltage DC current suitable for the LEDs
    Manufacturing Technique: Die fabrication
  8. Electrolytic Capacitor
    Material: Aluminum can, electrolyte inside, plastic sleeve
    Function: Stores and releases energy, stabilizes DC voltage, and reduces flicker in the LED output
    Manufacturing Technique: Foil etching and forming, winding, can sealing
  9. Two Screws
    Material: Steel
    Function: Secure the LED board to the central housing
    Manufacturing Technique: Cold heading, thread rolling, electroplating

Dissassemble Process

  1. Shade Removal
    • The outer diffuser shade was detached from the housing by carefully bending and pulling it by hand.
    • Since the parts were friction-fit and bonded with a rubber-like adhesive, removal caused minor cracking and shattering of the plastic.
  1. Unscrewing the Fasteners
    • A screwdriver was used to remove the two screws securing the LED panel to the housing.
  1. LED Panel Removal
    • Pliers were inserted into the screw holes on the LED panel to grip, peel, and pull the panel away.
    • The panel was also partially glued to the housing, requiring additional force to separate it.
  1. Metal Base Removal
    • A utility knife was tapped along the edge of the steel screw base to gradually break the seal.
    • Once loosened, the steel shell was peeled back and separated from the plastic housing.
  1. Circuit Board Removal
    • Pliers were used to extract the driver PCB, which was loosely friction-fit inside the central housing.
  1. Electronic Component Removal
    • Pliers were also employed to detach the remaining electronic components from the PCB.

Interesting Takeaways

  1. Slotted Plastic Housing for Circuit Board Alignment
    The central plastic housing features tapered slots that transition from larger openings to narrower channels. This geometry guides the circuit board into position during assembly while ensuring that the board is securely held in place by friction fit. This approach reduces the need for additional fasteners, simplifying assembly and lowering manufacturing costs, also ensuring adequate retention during the lightbulb’s operational lifespan.
  1. Use of a Metal Screw Base with Crimped Attachment
    Another notable design choice is the crimped interface between the metal screw base and the plastic housing. Instead of adhesives or screws, the base is mechanically deformed around the housing to create a strong, permanent connection. This ensures mechanical durability and also streamlines high-volume manufacturing, minimizing part count and assembly time.

Hello! This is Guangyu Wang(Zoe)

Hello! This is Guangyu Wang(Zoe), a new graduate member in SVA. Before studying in the USA, I was born and raised in Beijing, China. Since growing up, I have always been interested in “broke” something and observing the contents inside a product. This supports my future direction in the product design field. Driven by a strong desire to delve deeper into this field, I chose to study at Syracuse for five years, and I recently graduated with a major in Industrial Design. Nonetheless, at the spare time I love snowboarding, traveling, and swimming etc.. Also, playing with lego often for fun. Overall, I am a person who really enjoying the life and making each day count. Besides, talking about what I expect in this course, I would love to learn the real code writing! Thank you!

Here is my Instagram: geminicreamcheese

Samsung Remote Control Teardown

Samsung BN59-01391A Smart TV Remote Control teardown knolling

Plastic Shell (Front)

Material: Plastic

Manufacturing: Injection molded using a custom mold for shape and precision.

（Remove the screws with a small Phillips screwdriver. ）

Mounting Screws ×2

Material: Metal

Manufacturing: Metal wire is cold-forged to form the screw head, and threads are formed using a thread rolling machine for high speed and accuracy.
Surface is treated with black oxide coating or black nickel plating to create a rust-resistant and visually appealing black finish.

（Pry open the remote casing with a flathead screwdriver and a small knife.）

Plastic Shell (Back)

Material: Plastic

Manufacturing: Injection molded using a custom mold for shape and precision.

Plastic Button

Material: Plastic

Manufacturing: Molded via injection molding for shape and function.

Silicone Buttons

Material: Silicone

Manufacturing: Molded using compression molding, then printed color on the surface.

Solar Panel

Materials: Silicon, glass (low-iron tempered glass with Anti-Reflective Coating coating), plastic, metals, wires with rubber tubing

Manufacturing: Layers of silicon cells are sandwiched between tempered glass and protective plastic sheets. Electrical wires and rubber tubing are added for connectivity and sealing.

Printed Circuit Board

Materials: Core of non-conductive material: Fiberglass-epoxy composite (FR4), copper traces, solder mask

Manufacturing: The fabrication involves imaging and etching copper layers, drilling holes, plating with copper, and laminating layers to form the base circuit. The board is etched with copper circuits, and components are soldered on via wave soldering or reflow techniques.

Chip:
Atmosic ATM2231U — an extreme low-power Bluetooth 5.0 system-on-a-chip (SoC) designed for Internet of Things (IoT) applications. Specifically engineered to extend battery life in wireless devices.
Winbond 25Q40EWNIG — 4-megabit high-performance serial NOR flash memory chips.
PJ2086MB210 — no data found
BQ505 — no data found

Tools and techniques used to take it apart: Phillips screwdriver, flathead screwdriver, craft knife.

two design elements that interest me：

One interesting design element is the silicone button, which appears to be made from two differently colored silicone parts: a translucent base and an opaque white key cap. I imagine the white silicone is placed into the mold first, followed by the injection of transparent silicone to encapsulate it. I’m not sure why the designer chose this approach, it may be for cost-efficiency—by limiting the amount of white silicone pigment used—while still maintaining the desired appearance on the surface.

Another interesting design is how the two VPC batteries are connected to the PCB. They are directly soldered onto the board with four solder joints, which makes the setup straightforward and easy to identify. However, this also leads to a potential weakness—these connection points are more prone to damage or disconnection, especially with frequent handling or over long-term use. It reminds me of my Apple Magic Keyboard can’t charge, so I couldn’t use the Bluetooth connection. I suspect that one of its solder joints may have come loose. I think the designer may have chosen this method for its speed and simplicity in assembly. It also makes repair or inspection relatively easy, as the joints are clearly exposed and accessible.

Wini Jeng

Name: Wini Jeng

From: Taiwan / Queens

Before coming to PoD: Senior System Administrator at the School of Visual Arts (SVA), BFA Animation department.

Background: Wini holds dual degrees in Computer Science (from Taiwan) and Computer Arts, 3D and VFX (BFA from SVA), giving her a unique foundation in both technology and creative arts.

Interests: Making stop motion & puppets, yoga, and cooking vegetarian food.

Most looking forward to: I am most looking forward to the hands-on opportunity to be creative and bring my ideas to life.

Most apprehensive about: My biggest apprehension is managing my time effectively to keep up with the course demands.

IG:redgeroro

From Lauren🦎

Hi, this is Lauren // Lo

  • born and raised in Queens, New York with roots in St. Catherine, Jamaica
  • studied computer science and interaction design at GWU
  • interned as an experience strategist with Code and Theory and then moved into freelance design (ux/ui +product +production)
  • i love making collages with paper, digital tools and video
  • favorite foods -> eating is one of my favorite pastimes so i have many favorites, top 3 are a good kbbq + anything soupy + saucy + jamaican oxtail

    I’m looking forward to making tangible projects that can be easily recognized as my work. I enjoy making things that have cultural resonance and encourage some form of storytelling. I imagine the things I have made exist in a carefully curated world and i’m excited to use this class as a way to expand on that. I have less interest in the creation of soft products. As someone who has avoided learning how to sew for most of my life that is where most of my apprehension lies. It is exciting that my first sewing project will be to make a plushie.

Hi! I’m Manya.

I’m a multidisciplinary designer based in Brooklyn. I grew up in a small Connecticut town, halfway between New York City and Boston. In college, I studied biology and competed on the cross-country and track teams. I then attended design school in Atlanta before moving to Brooklyn to begin my professional career. Before joining PoD, I focused primarily on graphic design. Most recently, I was at Mother Design, where I specialized in branding and systems.

Outside of work and school, I enjoy spending time with my dog, Frankie, and watching him interact with the world. I maintain a running practice as a way to challenge myself and ensure I spend time outside.

I am cognizant that there might be a steeper learning curve towards the beginning of this course, as most of this is new to me. However, I’m looking forward to gaining a better understanding of how things work and potentially finding a new avenue of interest that will extend beyond this class.

@manyaswick

Hi I’m Jiayi Wang

I’m an illustrator and designer from Zhejiang, China, currently based in New York. I’m a cat person and love all kinds of desert. I graduated with honors from Parsons School of Design with a BFA in Integrated Design. Before joining the MFA Products of Design program, I worked as a product designer at CHEECASE, where I developed luggage illustrations, backpack colorways, and bilingual promotional materials. 

I’m interested in illustrated merchandise and stationery. Creates playful, purposeful visuals—turning paper goods, stickers, and packaging into small moments of joy in everyday life. I design new stickers as my business cards every year for fun.

I’m looking forward to exploring electronics and gaining hands-on experience with both coding and physical making for the first time. I’m excited to challenge myself and learn new technical skills that can expand my creativity.

My Instagram: jayw1027

Hiii It’s Anusha (nush) 🎀

From: California Age: 24 Degree: BFA Graphic Design (2023)

I am versed at most traditional fine art mediums, except sculpture- I am NOT good at that. I worked for a year after graduating at a Theatre Company as a set designer and am now doing freelance graphic/web design + I tattoo on the side! I am always eager to learn new skills and crafts and am so excited to find myself in a masters program that will expedite that process. My favorite avenue of graphic design is package design for food, bev, toys, kits, beauty products, etc.

I enjoy cooking, junk journaling, lino printing, modeling, styling clothes, writing, singing, and painting. I love sushi and hot pot the most. My friends are my family and I also have a sweet tuxedo boy. I collect interesting shoes and I enjoy horror movies and musicals. I am passionate about all groups of people being accurately represented in media and in the everyday tools we use.

Dreams I have include working as a Creative Director for Independent music artists, balancing tattooing with that, publishing my writing, designing a cookbook, and being on a reality TV show!

Links!

Portfolio Website: https://readymag.website/u1350593041/anushasowda/

Art Instagram: https://www.instagram.com/nushaverseink/

Personal Instagram: https://www.instagram.com/nushaverse/

Hi! I’m Mallika!

I am a design student from India with a Bachelor of Design degree and a diverse cultural background, having grown up in different parts of India. I graduated from the National Institute of Fashion Technology (New Delhi) in 2023 with a Major in Fashion & Lifestyle Accessories, along with a Minor in Space Display & Presentation Design.

My formal education in design exposed me to the lateral horizons of User-centric  Design, Packaging design, Design for Social Innovation, Branding, and Visual Communication, while my innate interest has always been in Lifestyle Accessories and Furniture. I was previously working as a furniture designer at a luxury furniture company in India – Wriver, where my role was to manage the Furniture Accessories vertical within the company. I, thereby contributed to the entire lifecycle of product development, from initial conceptualization to final visualization. One of the products that I made for the company was recently awarded the SIT Design Award 2025, which was an exciting achievement for me!

Throughout my journey with design, my thorough design process has been my constant companion. The tangibility of design has made the journey of my designs my means of expressing myself. Some of my hobbies include engaging in creative pursuits, journaling, exploring new places, trying new foods, and organizing things.

Having had no background or experience in computer science or coding, I am quite excited about learning how to code and integrate electronics into product design, however, the challenge of exploring a new field is also seemingly daunting.

I’m Batu

Hi! I’m Batu. I’m originally from Ankara, Türkiye, and I recently graduated from CCA with a degree in Animation. Before joining PoD, I’ve been working across different mediums—mostly animation, furniture, and design—because I love telling stories in more than one way.

Some of my favorite things to make are animated shorts, visuals, and video edits for artists, furniture designs, and multidisciplinary projects. Outside of school, I love playing basketball and DJ’ing. I do miss eating In-N-Out after moving from California, but I guess I can settle for Shake Shack here too.

In this course, I’m mostly looking forward to merging my TouchDesigner knowledge with Arduino and exploring how interactive systems can expand my practice.

@batualpas