
Designing and fabricating a unique lighting system for a specified use
My goal for this project was to create something beautiful but functional, and serve a purpose larger than just lighting. The concept I came up with was an expanding chandelier. The idea was that this could be a complementary piece to expanding or fold out tables, and would fit especially well in minimalist or small studio apartments. In this context, the user could adapt their lighting situation in a matter of seconds to accommodate different environments. E.g.: A large dinner gathering versus studying at your desk. While the final product does not hang from the ceiling as I originally intended, I have found that keeping the piece on a table allows for much more flexibility with the light fixture, as it can not only expand and contract, but can also flip or stand vertically.


The process from ideation to finished project was not perfectly linear. I had originally envisioned only having 1 row of scissor like wood pieces, until I got inspired by my drying rack with dual rows, and I liked the look and stability of that much more.
I had many prototypes that helped guide my construction. Some failed, some worked very well, but they were all very informative. Being able to make physical products was an essential part of my process.
The basic frame of the structure is made up of 8, identical wood pieces. Each piece is 11 1/2 inches long, 1 inch wide, and have 3 holes. The inner hole is where the wood pieces connect to one another (2, 3D printed pieces run through the hole, keeping the wood firmly in place) and the outer ones are where solid wooden dowels and hollow 3D printed cylinders connect.
Knowing that these wood pieces needed to be exactly the same to ensure consistency for aesthetics and mechanical purposes, I figured the CNC mill would be the best tool for helping me cut these pieces. I designed one of the "legs" on SolidWorks and exported it as a DXF file for the mill to read. The CNC mach proved very difficult as I needed to be supervised when using the machine and the CNC router itself was very finicky. After many failed attempts, I resorted to using the laser cutter. While this left a burnt edge, it was the only working solution.

I spent upwards of 3 hours sanding and preparing all of my pieces for assembly. This was time well spent though, as once I actually set out to construct the fixture it went very smoothly and all the parts fit together nicely.

Once I had tested the mechanics enough and settled on a solid solution, I got to the task of integrating my lighting system. I theorized that I could have a light strip run back and forth along the inside of the wood frame on the pieces that were not bisected. This would allow the strip to sit flush on the wood.
I first purchased an LED with staggered lights set 3/4 inch apart from each other, which was too dim and was not used for the final but was helpful as it showed me I could not just run the strip through the 3D printed cylinders I had made. When the wood contracted, the strip would get smushed, and eventually one segment of it broke and would not light up. This prompted my decision to use clasps, one side that would connect to wires and one side that would clip onto the copper plating on the LED.

While the connection was much better with the clips, it still caused problems as any slight tension on the clasp or wires would cause the light to flicker, and sometimes stall until the piece was returned to a position where the clasps could all sit flat. I used the knowledge gained from Project 3 and set out on the tedious task of soldering all of my LEDs to my wires, which ended up being a hugely successful decision as the lighting was infinitely more stable.
With the mechanics and electronic elements all accounted for, the final step was the ornamentation of the expanding light fixture. I knew I wanted to have a lampshade cover run around the side of the piece to help diffuse the light (By this point I had switched to a much stronger LED strip with continuous LEDs). Because of the unique geometry and changing conditions of the light I couldn’t merely affix the fabric directly to the wood. At first I tried using strings tied from one side of the covering to the other, hoping to use tension as a way of holding both the fabric up and keeping it down. However the porous nature of the fabric gave way and the string, once pulled tight enough, slipped through.

I then theorized that I could weave the fabric through small wooden dowels held in place by a central dowel running from one end of the wood to another where the pieces bisected one another. This solution worked perfectly, and looks really clean.

When they fabric is woven through, you can only see the central dowel (in this photo the bottom part of the fabric sheet is not woven through). This system also allows for some flexibility when the fixture expands and closes.



