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Lamp Design Project: Day 13 - Final Assembly

Hello Again,

This will be the final installment for the lamp project, save for some nice studio glamour pictures. Its been a while but we had some parts in the mail and had to wait our turn on the laser cutter, so here it is, the final assembly and use of our finished lamp. Enjoy!


A package came in the mail from LED shoppe. All the way from Hong Kong!


In an effort to make LED technology accessible in a kit form, we selected this bulb for our lamp. 60 LEDs attached to a E27 socket. Out of the box ready to go on 110v, no soldering required.


This picture shows two prototype lamp heads that broke during assembly. The one on the left broke near the spiral cut for the lamp shade, we thickened that section up on the head on the right but the mounting points are still weak. Lets see if we can improve the design.


Some gussets on the head, and redesigned side brackets should help to strengthen things up.


This is all of the parts for the final lamp, laid out and ready for assembly. A collection of laser cut acrylic, machined wood members, a laser cut wood veneer shade, and a few, widely available purchased hardware parts.


This is the glue that we will use to assemble the acrylic side bracket pieces that need bonded together.


Using the spring pin to help with alignment, some acrylic cement is dropped in between the pieces, which are then aligned and held together for 5 min to ensure a secure bond.


Two wood screws hold a stamped steel table clamp bracket to the lower wooden member. A table mounted lamp offers secure positioning while avoiding shipping/moving a heavy weighted base.


The lower member is attached to the lower acrylic side brackets. The 5lb spring is slipped over the pin before attaching the second side plate.


In the next step we will attach the two upper wooden members to the lower half with a 1/4 inch bolt and thumb screw. Available at any hardware store, when done right, these screws can be nice simple detail.


The upper acrylic side brackets are attached to the other end of the spring. Then we stretch the spring to reach the brackets to the end of the wooden members.


And assemble the wooden member, the lamp head arm. Now to assemble the head.


The side brackets fit into place on the main head piece. They are then bonded with acrylic cement.


We attach bare wire leads to a purchased E27 socket. Again we didn't make these parts, but a little searching will turn up economical and aesthetically pleasing parts.


Heres what the head will look like with the socket and bulb installed. Functional, but a little naked.


We laser cut a half-tone pattern into the bottom edge of this wood veneer piece. It will be slipped into the spiral cut into the head.


Gently insert one end and gradually roll up the shade. It takes a little patience, but will slip right in when done right.


The switch pin secures the potion of the shade in relation to the socket.


Add the bulb and...


Test to make sure we have power. Good to go!


Another 1/4 inch bolt and 6 washers will attach the head to the end of the wooden arm.


This last step will be easiest with the lamp attached to the table.


Adding washers in the appropriate spots will allow the head to articulate smoothly and hold its position.


Done! How about some contextual shots.


The lamp shade creates a beautiful pattern, both at point and in the light emitted on the table.


Lights on. Fits well with our IKEA desk. The lamp moves smoothly, holds its position, and can cover nearly every inch of this table with light.


Lights off, Fed puts the lamp to use! On to the next project.

Look for this lamp in kit form on your favorite DIY online hardware store soon. I hope you have enjoyed seeing our design process, it has been a pleasure to share. Let us know what you think. Keep on making!

Regards,

Dan + Fed