Personal project:

From CAD design to functional hardware: a smart lamp switch

  • CAD design
  • Hardware Prototyping
  • IoT
  • 3D printing

I designed and built a custom smart switch enclosure for a conventional lamp, enabling both smart-home control and physical interaction. Through this project, I gained hands-on experience designing at the intersection of hardware, software, and user experience.

Assembly of a custom smart switch enclosure for a conventional lamp.

The problem

A friend owned a standard lamp with a conventional light bulb and wanted to integrate it into an existing smart home setup.

The requirements were simple:

  • Control the lamp through the existing home automation system
  • Avoid additional hubs, bridges, or complex setup
  • Preserve the familiar manual switch interaction
  • Keep the solution affordable and easy to maintain

 

Exploring the solution

Concept

Rather than replacing the lamp or modifying its internal electronics, I explored how the existing button could be reused.

The concept was to design a custom enclosure that would fit around the existing switch while housing the smart switch hardware. This approach preserved the original interaction while adding smart-home functionality.

I began with sketches and rough concepts before moving into CAD modelling.

Sketch of the a custom enclosure.
Preview of the CAD design.

 

As with many physical prototypes, the first versions revealed issues that weren't obvious in the digital model.

  • Structural weaknesses
  • Print quality
  • Tolerances in 3D printing
3D printer printing prototype.
3D print variants.

 

Assembly and installation

After validating the design and refining the enclosure, the final components were printed, assembled, and installed.

 

Outcome

The lamp can now be controlled through the home's automation system as well as through the original manual button.

Photo of the lamp with smart switch.

Although the final enclosure is bulkier than an ideal production-ready solution, it met the functional requirements and demonstrated the feasibility of the concept.

Most importantly, the project reinforced my interest in designing experiences that bridge software and hardware, where digital automation complements familiar physical interactions rather than replacing them.

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