Inspired by the vine flower Thunbergia, I developed this flower lamp. Hand-made hinges on the petals redirect light at a gentle push. The form, materials, and treatment create a pleasing ambient light, and the petals create an engaging while useful light source. I created Thunbergia for the introduction to manufacturing class, ME 203, during Fall of 2011.
The biggest design challenge in building Thunbergia was developing hinges that satisfied my vision. I imagined cantilevering a piece of aluminum sheet metal that remains stationary until shifted gently. I used setscrews in an assembly of brass bearings on a steel rod to create a lasting effect. The mill and lathe were especially useful in this phase.
The biggest design challenge in building Thunbergia was developing hinges that satisfied my vision. I imagined cantilevering a piece of aluminum sheet metal that remains stationary until shifted gently. I used setscrews in an assembly of brass bearings on a steel rod to create a lasting effect. The mill and lathe were especially useful in this phase.
Finished hinges
Early sketches for hinge design. Click to enlarge.
Sanding the turned hinges
To create the opening and closing expression of the flower, I modeled the lamp on Solidworks. Once I developed a pattern for the petals, I projected it onto aluminum sheet metal and rolled the shape to create five near-identical petals. The assembly was sanded for days and anodized.
Key learning:
- Work with the final material early.
- Leave time to sand and anodize because careful presentation makes products incredible.
- Sometimes things don’t go as planned: be flexible.
Key learning:
- Work with the final material early.
- Leave time to sand and anodize because careful presentation makes products incredible.
- Sometimes things don’t go as planned: be flexible.
Solidworks design of petals
Finished petals