Customizing an aluminum metal table lamp centers on shapes that fit aluminum’s processability (e.g., one-piece molding, lightweight structures) and functions integrated with aluminum’s properties (e.g., heat dissipation, corrosion resistance). The process has 6 core stages, with key details for shape and function highlighted in each step.

      1. Demand Confirmation: Lock Shape Feasibility & Function Requirements

Aluminum’s light weight (1/3 the density of iron) and good ductility determine its shape limits and function priorities. Focus on 2 core aspects:

Shape Details to Confirm

Basic structure direction: Decide on shape types that align with aluminum’s strengths:

Minimalist one-piece: e.g., a curved aluminum base + thin lamp pole (aluminum can be extruded into long, thin structures without bending easily).

Hollow geometric: e.g., a hexagonal aluminum base or hollow cylindrical lamp pole (aluminum is easy to hollow out, reducing overall weight while maintaining stability).

Detachable modular: e.g., a base and lamp pole connected by aluminum screws (avoid welding aluminum, which is high-cost; modular design is easier for assembly/disassembly).

Size constraints: Aluminum lamp bases need a minimum thickness of 2-3mm (too thin will cause instability); lamp poles are usually 8-12mm in diameter (thin but rigid enough).

Function Details to Confirm

Must-have functions (aligned with aluminum’s properties):

Heat dissipation optimization: If using high-power LEDs, confirm whether to integrate aluminum’s natural heat conductivity—e.g., design the lamp pole as a heat sink (no extra heat dissipation parts needed).

Corrosion resistance adaptation: If used in humid environments (e.g., bedroom near a window), confirm no extra anti-rust treatment (aluminum forms a natural oxide film, so basic anti-corrosion is sufficient).

Optional functions:

Dimming mode: Touch dimming (install a touch sensor on the aluminum base—aluminum’s conductivity requires insulating the sensor from the base) or knob dimming (embed a knob in the aluminum lamp pole).

USB charging: Reserve a 1-2 port USB slot in the aluminum base (aluminum’s easy drilling allows precise slotting without damaging the structure).

Adjustable lamp head: Use aluminum hinges (lightweight, rust-proof) to connect the lamp head and pole, supporting 0-90° rotation.

         2. Design Finalization: Translate Shape & Function into Aluminum-Compatible Drawings

The design must resolve "shape processability" and "function embedding" for aluminum, with 2 key steps:

Shape Design Focus

3D modeling for aluminum processing:

Mark aluminum-specific parameters: e.g., hollow lamp pole’s inner diameter (at least 10mm to hide wires), one-piece base’s fillet (R2-R3mm, avoiding sharp edges—aluminum’s cutting is easy but sharp edges are prone to deformation).

Avoid complex undercuts: Aluminum’s die-casting or extrusion is poor at handling deep undercuts (e.g., a base with a hidden groove deeper than 5mm may require secondary processing).

Structure simulation: Test whether the aluminum shape is stable—e.g., a tall, thin lamp pole (height >50cm) needs to thicken the bottom 1/3 of the pole (from 8mm to 12mm) to prevent tipping (aluminum’s light weight increases instability risk).

Function Design Focus

Function embedding design:

Heat dissipation: If the lamp head uses LED lamp beads, design the aluminum lamp head as a "honeycomb structure" (increases heat dissipation area—aluminum’s thermal conductivity will transfer heat quickly).

Circuit hiding: Design a hollow channel in the aluminum lamp pole (diameter 8mm) to thread wires, and reserve a 2cm deep cavity in the base for the dimmer module/USB motherboard.

Interface positioning: Mark the exact position of USB ports (e.g., 2cm above the base’s bottom edge, 1cm from the side) and touch sensors (center of the base, 3cm in diameter—avoid overlapping with internal circuits).

        3. Aluminum Processing: Shape Formation (Core for Aluminum)

Aluminum’s processing methods directly determine the final shape; choose processes based on shape complexity, with 3 common options:

Processing Method Suitable Shape Types Shape Processing Details Function Compatibility

Extrusion Molding Long, uniform structures (e.g., straight lamp poles, rectangular bases) Heat aluminum ingots to 500-600℃, extrude through a mold (custom mold for pole diameter/section shape). Cut to length (e.g., 40cm for lamp poles) after extrusion. Easy to drill holes for switches/USB ports; hollow extrusion can directly hide wires.

CNC Milling Complex 3D shapes (e.g., curved bases, lamp heads with honeycomb grooves) Use a CNC machine to carve aluminum blocks (thickness 15-25mm) into the designed shape. Precision up to 0.1mm—suitable for small details (e.g., a concave switch slot). Can mill cavities for dimmer modules; surface is smooth enough for touch sensors.

Die-Casting Intricate integrated shapes (e.g., base + short pole one-piece design) Inject molten aluminum (660℃ melting point) into a steel mold, cool and demold. Suitable for shapes with small protrusions (e.g., a base with anti-slip bumps). Mold can pre-reserve USB port slots; no need for assembly (reduces loose parts).

Post-Processing for Shape

Deburring: Use a CNC router or sandblaster to remove burrs from extrusion/casting (aluminum’s softness makes burrs easy to clean, ensuring no scratches on hands).

Shape correction: For extruded lamp poles, use a straightening machine to adjust bending (aluminum is prone to slight deformation during cooling—straightness error must be <0.5mm).

           4. Surface Treatment: Enhance Shape Texture & Function Durability

Aluminum’s surface treatment affects both shape aesthetics and function (e.g., touch sensitivity), with 4 key processes:

Shape-Related Treatment

Brushing: Create a linear texture along the shape (e.g., a curved lamp pole uses "arc brushing" to follow the curve—enhances the sense of flow). Suitable for minimalist shapes.

Sandblasting: Form a uniform matte surface (Ra 1.6-3.2 roughness) for complex shapes (e.g., honeycomb lamp heads)—hides minor shape imperfections (e.g., slight unevenness from CNC milling).

Function-Related Treatment

Anodizing: Form a 5-20μm oxide film on the surface (aluminum’s core anti-corrosion process). For touch-sensitive areas (e.g., base), use "hard anodizing" (film thickness >15μm) to avoid scratches affecting touch function.

Color coating: If adding color, use "electrophoretic coating" (adheres tightly to aluminum, no peeling) instead of spray painting. For USB port areas, leave a 1cm uncoated section (avoids coating affecting USB contact).

          5. Function Integration: Embed Functions into Aluminum Structure

Aluminum’s lightweight and hollowability make function installation easier; focus on 3 key steps:

Heat Dissipation & Light Source Installation

If using high-power LEDs (≥10W), attach the LED board directly to the aluminum lamp head (aluminum acts as a heat sink—no need for extra heat dissipation fans).

For low-power LEDs (≤5W), install the bulb in an aluminum lamp holder (hollowed out to allow heat to escape—prevents overheating from shortening bulb life).

Circuit & Control Installation

Thread the power cord through the hollow aluminum pole, connect it to the dimmer module (installed in the base’s pre-reserved cavity).

Glue the touch sensor to the anodized aluminum base (ensure the sensor is aligned with the uncoated area—guarantees sensitivity).

Solder the USB motherboard to the circuit, then fix it in the base’s USB slot (use aluminum screws—matches the material and avoids rust).

Auxiliary Function Installation

Stick 3-4 silicone anti-slip pads on the aluminum base’s bottom (align with the base’s shape—e.g., a circular base uses 4 pads evenly distributed).

Install an aluminum toggle switch on the lamp pole (drill a 6mm hole—switch size matches the hole to avoid wobbling).

       6. Quality Inspection: Verify Shape Stability & Function Reliability

Aluminum’s characteristics require targeted inspections for shape and function:

Shape Inspection

Stability test: Place the lamp on a 15° inclined table—if it doesn’t tip, the shape (e.g., base weight distribution, pole thickness) is qualified.

Dimensional check: Use a caliper to measure key parts (e.g., lamp pole diameter, base thickness)—tolerance must be within ±0.3mm (aluminum’s processing precision is high, so strict tolerance ensures shape consistency).

      Function Inspection

Heat dissipation test: Turn on the lamp at maximum brightness for 2 hours—measure the aluminum lamp head’s temperature (should be <50℃; aluminum’s thermal conductivity should prevent overheating).

Function test:

Touch the base 3 times to test dimming (must switch smoothly between low/medium/high brightness).

Plug a phone into the USB port—charging current should be stable (no fluctuation).

Durability test: Rotate the adjustable lamp head 50 times—aluminum hinges should not loosen (aluminum’s wear resistance is lower than iron, so hinges need to pass wear tests).

I can help you create a aluminum table lamp shape-function matching guide that lists which aluminum processing methods (extrusion/CNC/die-casting) are suitable for different shapes, and which functions (dimming/USB/heat dissipation) can be integrated with each shape. Do you need this guide?