How it’s made
The head is made from thick metal using the original old molds from the factory that were used more than 40 years ago. They are stamped using the same old machines that we bought and brought to our shop from local and old factories. We made the head out of steel and the headlight has industrial grade thick glass. All our headlights are recycled or reused parts of old vehicles as we wanted to keep the product as original as possible.
The front of the headlight is made from 3 mm thick glass. Most of the glass is recycled from old headlights as it was common to break so stocks were made available. The back and front of the headlight are stamped separately and after that no less than 32 operations are added to get to the final shape. A total of 24 molds and tools are used to make the headlight.
The neck is the only exposed part so it is made out of polished aluminum so it will never rust. This part is made by injecting aluminium into a mold. We chose aluminium as it would not rust, it has a low weight and high strength.
The body is made of 100% recycled high-density polyethylene. To keep the polyethylene consumption as low as possible the body is hollow. To get perfect balance, you need to fill the interior with sand, salt or similar materials to get to the weight of 4.3 kg (9.5 pounds).
The rubber shoes are made from recycled rubber used in other products so nothing is lost.
The leather accessories are also made from leather leftovers. Even the box is made from recycled cardboard.
The cord is made from textile material and uses high quality plugs and wires.
The painting is done individually for every customized item. Artsy, Army or Zombie styles are done by hand and we are extremely careful with details. The paint we use is closely chosen to be UV resistant and friendly with the environment also. The metal head is electrostatic painted and the body is hand painted with non toxic water based paint.
Customize all the way! You can choose from simple color, simple color with a logo, color with an army, artsy, zombie style and we can also add your initials on it. This is the most personal a desk buddy can get!
The paint we use is water-based and it comes in multiple coats. A base coat serves is the first step and then 2 layers of paint are added for extra coverage and color consistency.
Two layers of clear coat will protect against wear and scratches. The second layer of clear coat is UV resistant so if exposed to sunlight The Lampster will not alter its color.
For models that have a logo there will be a third layer of coating to protect the customized design.
The lamp uses a total of 128 Osram LEDs. Out of that there are 48 white LEDs and 72 rgb. The 48 white LEDs are split in 24 warm whites and 24 cold whites so you can find the perfect balance for different activities. The white light has a power of 8.5 Wats and it is the equivalent of over 70 Wats (incandescent). The RGB uses 72 LEDs to get you the color you desire. A total of 4W of power (over 40 Wats-incandescent).
The lights were specially developed in the lab for the Lampster. The challenge was to convert the light emitting capacities of the headlight, that were designed for long spread and reach and to make them become the perfect day to day use lamp. As you saw the original glass has some embossed lines that are used in the headlight to spread the light and cast a small shadow at close range. We needed a special filter so we can make the shadow disappear while keeping the original glass and design.
The light was tested and tuned in the lab and everything was taken into consideration. Even heat dissipation is a big factor. While for the original headlight it wasn’t an issue, when it is used as a lamp and the head is touched by hand to change the intensity or to change the orientation is very important that the temperature will not pass 40 degrees on touch. That was done by using powerful LEDs at low voltage so they will emit less heat. This also extends considerably to the life of the LEDs as no heat is affecting them.
As a safety feature the cip is monitoring the temperature and if it reaches 60 degrees inside the core it will shut down the lamp. For example, if the lamp is under heavy direct sunlight and it is at maximum power and therefore it will heat, that will be detected and the lamp will turn off.
The cable is also 2.5 m long so you have a lot of flexibility while using The Lampster.
Attention to details
It was very challenging to make an object that was not designed for that specific purpose you are planning to use it for and to also make it to be one of the best lights on the market. So besides the design of the lamp we are also taking into account the light’s features. That is how you have not only one of the coolest designs but you get perfect functionality also.