Objective: To create a lamp using the woodshop tools.

Timeline and Group Size: This was a four week project with three people.

My Role and Responsibilities: I took the lead on design, testing and class presentations. I created the initial sketches, assembly diagram, order of operations and bill of materials. I also took the lead on creating the test piece and final prototypes.

This was the inspiration. I wanted to create a wall of light that was customizable.

The end result fits nicely on a desk or end table in a variety of configurations and can be dimmed from a task light to a mood light.

Process Summary:

Developed initial sketches and computer models to get an idea of feasible scale.
Created a test piece to work out processes and materials for the final product.
Crafted a functional prototype using the lessons learned from the test piece.

Testing

We worked out the final concept with computer models, sketches and test pieces

The initial idea was scaled down due to time and cost

Initial Stain Test

Made out of 10/4 poplar because it was inexpensive and locally available

Vinyl Tubing Connections

Different Edge Treatments and Colorings

Wiring

Custom spacing required creating a custom lighting solution made of LED lights with a dimmer added for additional customization.

Frosted Acrylic

Height Test

Shape Test

The conclusions of the test pieces and resolutions for final piece:

The acrylic was too clear---> I sourced some white acrylic made for LED signs
The oil stain was too dark, took to long to dry and did not cover evenly---> We used a lighter, reddish gel stain that dried quickly, offered more even coverage and disguised the green cast of poplar.
Bevelled edges cut down on the blocky feel of the units---> We decided to bevel all eight edges.
Contrasting stained and unstained parts were distracting---> We made the units a uniform color.
Vinyl tubing connections were not sturdy enough---> Alternating aluminum tubing was added.
Final scale would be 18" high x 26" long.

Final Prototype

We cleaned the 10/4 poplar to 2" x 3", routed out 1/2" by 1/2" channels in each corner and cut 36 two inch blocks.

We routed out 1/8" channels for the acrylic windows and drilled the holes for the wire and tubing connections following the order of operations

I soldered together three sets of 6 LED light strips with 6" wire in between and a 24" long piece of wire at the end to help us thread them through later

We used a gel stain in a slightly red toned cedar finish to counteract the greenish hue of the poplar. My other teammate, Wanshan, did the initial staining of the insides of the units.

After they were stained and waxed we wired together three stacks of six alternating units with vinyl tubing connections, if I had this to do again I would have used aluminum here as well.

After unit assembly, routing out the bevelled corners and sanding to 400 grit, they were ready for final staining.

We ran the long ends of the wire through connecting aluminum tubing and soldered the three sections together.

Once all the lights were working we could insert the final pieces of laser cut white acrylic and glue in the last wood corner piece.

We used a clear acrylic rod with laser cut ring stoppers on the top to connect the ends when it is in a continuous shape.

Modulux-Prototyping

Objective: To create a lamp using the woodshop tools.

Timeline and Group Size: This was a four week project with three people.

My Role and Responsibilities: I took the lead on design, testing and class presentations. I created the initial sketches, assembly diagram, order of operations and bill of materials. I also took the lead on creating the test piece and final prototypes.

Process Summary:

Developed initial sketches and computer models to get an idea of feasible scale.

Created a test piece to work out processes and materials for the final product.

Crafted a functional prototype using the lessons learned from the test piece.

Testing

Final Prototype