Real product-development case
Developing a Custom Rechargeable LED Module for a Portable Table Lamp
How a Ø65 mm lamp opening, 2200K CRI 90+ light, three-step dimming, rechargeable power and serviceability were translated into a practical sample-development brief.
Project update: 2500K selected after samples, followed by a 20-unit order →An architect and product designer needed a complete internal LED and electronics assembly for a new portable table lamp. The goal was not a loose collection of components, but a rechargeable, ready-to-integrate light engine that could be installed through the lamp's approximately 65 mm bottom opening and serviced later. Compact LED modules can be integrated into many translucent or light-diffusing housings, but the fit, optics, charging access and thermal conditions still need to be matched to each enclosure.
The buyer moved from an initial 2200K brief to a 2500K selection after receiving samples, then confirmed 20 matching modules and reported making the payment. The agreed follow-up configuration was 60 mm, 2500K warm white, USB-C charging and three-step dimming, unchanged from the previously supplied samples.
Customer brief
The requested function was defined before selecting the hardware.
The following values document the development request. They are original targets for engineering and sample validation. The selected follow-up configuration is recorded separately below; original targets should not be read as measured final performance.
| Application | Custom portable table lamp |
|---|---|
| Lamp opening | Approximately Ø65 mm |
| Maximum available diameter | Approximately Ø70 mm |
| White light | 2200K warm white, CRI 90+ requested |
| Light character | Soft, even ambient light |
| Output | Approximately 1–2 W requested |
| Dimming | 100% / 65% / 35% / OFF requested |
| Target runtime | Approximately 8–10 hours |
| Charging | USB-C or magnetic charging requested |
| Serviceability | Replaceable battery and preferably a replaceable LED module |
| Initial production | Approximately 50–100 units, with potential for larger quantities |
| Original project stage | Sample development; subsequently progressed to a confirmed 20-unit order |
Mechanical fit
The opening size starts the discussion, but does not define the complete module.
The lamp had an approximately Ø65 mm opening and could accept a complete internal assembly up to roughly Ø70 mm, subject to the lamp geometry. The engineering check must separate the body diameter that passes through the opening from the flange, mounting method, diffuser, charging access and available depth.
A CAD drawing or physical lamp sample is the safest way to confirm clearances and decide whether the module should be removable from below or retained inside the lamp body.
Light quality
The initial 2200K request became a 2500K selection after samples.
A warm 2200K appearance and CRI 90+ are specific white-light requirements. They should be confirmed from the selected LEDs, driver current and diffuser—not assumed from a standard RGBW module. The prototype also needs a visual check inside the real lampshade because diffusion, material thickness and internal distance affect brightness and uniformity.
After receiving the samples, the customer chose 2500K warm white. The follow-up order therefore specified 2500K rather than the initial 2200K request. Sample review gave the buyer a concrete light version to select before starting a small production run. This record does not provide a measured CRI result.
The requested 100%, 65% and 35% steps can be implemented as a simple product-specific control sequence, with OFF after the third brightness level. The final percentages and perceived difference should be checked on the sample.
Battery and charging
Runtime must be validated against the real power profile.
An 8–10-hour runtime target cannot be confirmed from LED wattage alone. Battery energy, driver efficiency, brightness level, thermal limits, protection circuitry and ageing margin all affect the result. The sample should be measured at each dimming level before the battery configuration is approved.
USB-C provides a familiar physical charging interface, while a magnetic connector can reduce repeated handling of a recessed socket. Either option still requires a matched charging circuit, safe lithium-battery protection and suitable product access.
Starting platform
The 60 mm platform progressed to a defined warm-white configuration.
Standard VC-LS60 uses a compact rechargeable RGBW architecture with a USB-C or DC charging option. For this project, the custom warm-white sample and follow-up configuration should be distinguished from the catalogue RGBW version. The final selected 2500K light and three-step dimming belong to this customer's module configuration, not every standard VC-LS60.
Prototype path
The sample order turns the written brief into measurable decisions.
The inquiry progressed to a paid sample order. That confirms a real development need, but it does not by itself confirm final production performance. The prototype stage should verify fit, light distribution, CCT and CRI, dimming, runtime, charging, temperature and service access inside the actual lamp.
The original brief anticipated approximately 50–100 units. When introducing the new lamp design, the buyer instead wanted to start with 20 and scale later. The later correspondence records agreement on that smaller order; it does not establish that the original quantity estimate was produced.
After sample review
The customer confirmed 20 units matching the 2500K samples.
The buyer said they were happy with the samples and wanted to continue the project at a smaller starting quantity. After discussing the custom-production requirements, the customer accepted a quotation for 20 modules and subsequently reported completing the bank transfer.
| Initial light request | 2200K warm white |
|---|---|
| Selection after receiving samples | 2500K warm white |
| Follow-up quantity | 20 modules |
| Module size | 60 mm |
| Charging | USB-C |
| Brightness control | Three-step dimming |
| Configuration request | Identical to the previously supplied samples, without changes |
Keeping the approved reference matters when a new lamp moves from samples to its first small run: record the chosen colour temperature, charging interface and dimming behaviour together. Three brightness steps do not mean three colour temperatures.
This was a project-specific quantity agreement, not a general 20-unit minimum for custom production. Production timing, shipment and feedback on these 20 units are not confirmed in the records supplied for this update.
Developing a rechargeable lamp or illuminated product?
Start with the opening, available depth, target light, runtime, charging preference and estimated quantity. Vcan can compare the brief with a standard platform and identify what needs to be customised.
Questions
Before developing a custom portable lamp module.
Does a 65 mm lamp opening require a 65 mm LED module?
Not necessarily. The part that enters the opening, the outer flange, mounting points and available depth can all have different dimensions. A drawing or sample check is needed before confirming the housing size.
Can the standard VC-LS60 be used unchanged for this lamp?
The catalogue model was the starting platform, not the complete custom specification. After receiving samples, this buyer chose a 60 mm, 2500K warm-white version with USB-C charging and three-step dimming, then requested 20 units identical to those samples. Other lamp projects still need their own configuration and fit review.
Why does this case mention both 2200K and 2500K?
2200K was the customer's initial request. After receiving the samples, the customer selected 2500K for the 20-unit follow-up order. These are two stages of the project, not two selectable colour-temperature settings on the ordered module.
Can a new lamp project start with 20 custom modules?
Vcan and this customer agreed an initial 20-unit order after the samples had been reviewed. That project-specific agreement does not establish a 20-unit minimum for every custom module. Confirm the configuration, component availability, quantity, quotation and schedule for your own project.
Can a rechargeable lamp use 2200K LEDs with CRI 90+?
Yes, subject to LED selection, thermal design, driver current, diffuser performance and supply availability. A prototype should be checked for colour quality, brightness, heat and visual uniformity before production approval.
Is USB-C or magnetic charging better for a portable table lamp?
USB-C is familiar and easy to source. Magnetic charging can simplify alignment and protect the product design from repeated connector handling. The better choice depends on enclosure access, charging electronics, appearance, service needs and the intended environment.
What information is needed to review a custom lamp module?
Start with the opening diameter, available internal depth, a drawing or clear product photos, target light colour and brightness, runtime, charging preference and estimated quantity. Vcan can identify any additional detail needed for the sample.
This case follows a real customer brief through samples, selection of 2500K and a confirmed 20-unit order with customer-reported payment. Customer identity and product-design details are omitted to protect project confidentiality. Dimensions in the original brief are development targets. They should be distinguished from the selected order configuration and from measured performance. For general selection criteria, see the rechargeable LED module buying guide.
