The Casinos Austria and Austrian Lotteries Group commissioned Philipp Aduatz for the design and realization of the world’s first 3D-printed film studio. In close collaboration with set designer Dominik Freynschlag and 3D concrete printing manufacturer incremental3d, a new and innovative application was realized through a unique structure using additive manufacturing and the latest LED technology.
Integrated LED Lighting
The main part of the lighting system are 14 LED strips inserted horizontally into prefabricated joints, which can be controlled by the RGB colour space in a variety of colours and colour gradients. By replacing the print layers with LED strips of the same thickness, the lighting technology could be perfectly integrated into the design. All LED elements are connected to the rest of the studio lighting via computer-aided control, creating an almost unlimited number of colour combinations.
"Components produced by additive manufacturing with concrete are not only suitable for building construction applications, but also offer completely new creative qualities and possibilities in interior design, particularly in the combination with LED-technology as this project demonstrates".
LED Technology and 3D Printing
Due to its material-saving properties, concrete 3D printing is considered a sustainable alternative to conventional concrete construction methods. Components produced by additive manufacturing with concrete are not only suitable for building construction applications, but also offer completely new creative qualities and possibilities in interior design, particularly in the combination with LED-technology as this project demonstrates.
3D Printing: Sustainable and Simplified
Due to its material-saving properties, concrete 3D printing is considered a sustainable alternative to conventional concrete construction methods. In addition, no formwork materials are required, so waste is reduced to a minimum. If no reinforcement is used, as is the case here with the film studio, any recycling is further simplified. The wall has a total weight of 3.500 kg. The external dimensions of the wall are: 630 cm width, 330 cm depth, 230 cm height.
Inspired by falling ribbons, the Flux Lamp is defined by harmonious lines and smooth geometric curves. Consisting of a series of draped ribbons, the lamp makes a stunning statement, giving this piece an intriguing, almost illusory lighting effect. The irregular ribbons of the lamp add movement to the form and by thus creating an architectural effect that always creates a different impression depending on the viewer’s perspective.
Revolutionary Design meets 3D Printing
Amsterdam-based industrial and parametric designer Gabi Potsa wanted to combine the revolutionary possibilities of 3D printing with unique design possibilities to create pieces that cross the line between sculpture and industrial design, resulting in unique objects that leave a long-lasting impression.
Complexity for Free
The complex geometry of Flux can be produced by 3D printing only. 3D printing allows production on demand and near the customer’s location, reducing emissions related to shipping and extra stock. The lamp was originally designed for Freshfiber, but due to the early closure of the company, the development came to a halt in the last stages of prototyping.
Shortlisted by Designmilk
In 2022, the design shaped by Entrive Studio made it to the Judges’ Shortlist of DesignMilk’s LAMP competition. The designer is currently looking for partners to launch the collection.
DiveDesign, a product development firm based in New Jersey and dedicated to empowering people and ideas through research, strategy, and emerging tec and Thomas Jefferson University based in Philadelphia, US, recently explored the beauty of light and 3D printing through a lighting product design competition. And the results were stunning.
Industrial Design meets Lighting Beauty
The industrial design students at the university, under guidance of their professor Lyn Godley created 12 unique designs of appealing pendant lamps. The exploration included the idea of optic diffusion as a natural result of the printing process; embracing the material/technique for what it is.
ICARUS by DiveDesign
All 12 of the designs were finally printed on DiveDesigns’ Filament Innovation ‘ICARUS’ with clear PET-G material. DiveDesign strategically develops meaningful products and brands that transform industries while keeping their customers at the forefront of the process. The highlights of the competition are currently showcased at the DiveDesign Studio.
All participants, these were sophomores, were blown away by the outcome, so are we!
Introducing the LimeLite One Motion® recessed ceiling rose offers installers a whole new way to mount and height-adjust 3D printed pendants. A simpler and easier way that takes minimal effort while achieving maximum savings in valuable time. A way that’s not just different – but also better!
LimeLite One Motion: A Next Generation Recessed Ceiling Rose
With the LimeLite One Motion, all the installer needs for a lighting cluster is to simply mark out the X & Y plus noting the Z coordinates supplied by the lighting designer, drill a 70mm hole at the marked spots and wire the pendant. Then, with (you guessed it…) ‘one motion’, the pendant can be installed and height-adjusted in record-breaking time.
What’s more, by using (say) FaceTime® on a mobile device, the installer can then consult directly with the designer to refine the heights and orientation of luminaires – all in real time and while on site. Job done.
The Role of 3D Printing
3D printing in the early stages of design and manufacturing gave us the ability to keep refining and perfecting the One Motion design. Meanwhile, using knowledge gained in this stage, Limelite concluded that manufacturing the One Motion on its 3D printers would slow their ability to unitize our “just in time” system. It would simply take too much time when bulk orders were required. Thinking forward, they knew they would inject mould these common parts.
LimeLite’s Advanced Manufacturing Hub
Limelite 3D printers enable their ‘Advanced Manufacturing Hub’ to produce different track lights, pendants and wall light covers, all of which have common parts, industry 4, thinking and design. As many readers would know, ‘Industry 4.0’ fundamentally changes the way in which businesses create and capture value. This shift is enabled by a set of technologies including autonomous robots, simulation technology, system integration, the Internet of Things (IoT), cybersecurity, cloud computing, additive manufacturing, augmented reality and big data.
Industry 4.0: A Major Driver for LimeLite Future Strategy
The more has been designed, the more the LimeLite team continues to dream. What they dream of now is better, more efficient and customer-friendly ways of doing business made possible by localization of manufacture – all made commercially feasible by 3D Printers in Advanced Manufacturing Hubs around the world.
LimeLite is dreaming BIG – and invites you to contact them to learn more!
Over recent years, the adoption of 3D printing technologies continues to rise, and an increased number of industries and businesses start to explore the possibilities for their needs. New collaborations and partnerships on a level of technology, materials, applications and manufacturing methods continue to evolve. Recently, Nexa3D and Henkel have joined the scene with the launch of three new high-performing polymers.Here’s the latest!
Nexa3D and Henkel – A Photopolymer Marriage
Early 2020, Henkel, a true collaborative materials firm, has never been shy to task on new adventures that help to take 3D printing to a next level. The collaboration with Nexa3D dates back to early 2020 when they released a medical-grade polypropylene-like 3D printing material (named ‘xMed412’), and a multipurpose photopolymer for rapid prototyping (‘xPRO410’). The latest generation of photopolymers that was recently launched, offers a durable solution for high-performance prototyping.
The recent developments came about with the goal to boost mass production capabilities for any industry, offering enhanced options for 3D printing a greater range of items from shoes to housings to packaging and much more.
New Materials – New Industries
There are three new material variations available, all of them suited for use with the Nexa NXE400 3D printer.The first material, xPP405-BLACK, is a semi-rigid print material with high-impact resistance. The material performs similar to propylene (unfilled). It is tough yet has a sleek industrial black finish and boasts 130 percent tensile elongation at failure. This material is well-suited for creating for example housings, enclosures, piping or packaging in manufacturing and engineering applications.
xPEEK147-BLACK, the other black alternative, is the preferred option when ‘toughness’ and a good surface finish are needed for tooling or molding applications. Whereas xPP405-BLACK is mainly developed for engineering and design environments, xPEEK black is initially developed keeping an eye on the direction of use in end-parts. Even for demanding applications, such as automotive industries, xPEEK147-BLACK is a fairly interesting material. The temperature resistance goes up to 230°C and it has high stiffness while providing long-term thermal stability with good solvent resistance and dimensional stability.
Clear 3D Printing for Entry Lighting Applications
While a black opaque material may be fine for a broad range of applications, having a clear material could be beneficial too in many situations. When creating ‘translucent objects’, such as 3D printing bottles, light pipes, packaging, or other products that need to include lighting applications, xPP405-CLEAR provides a see-through alternative. Again, ‘durability’ and ‘toughness’ are the keywords, along with having a high-impact resistance. The material offers a generally low heat deflection temperature between 50°C and 60°C with a 130 percent tensile elongation at failure.
Whether you are just starting to delve into 3D printing or looking for new material solutions, the partnership between Nexa3D and Henkel brings some interesting options to the table. Both companies are committed to democratizing access to scalable additive polymer solutions empowering customers to own their supply chain throughout their entire product life cycle. Starting from design to production and aftermarket success.
We’re always keen to see new options arrive that help to reduce the total cost of ownership, while delivering higher productivity, extended lifespan, and exceptional economics. At our end, we keep tracking the partnership with great interest!
FutureWave is a Belgium based product agency founded by designers and engineers with a passion for cutting-edge technology. With a deep background in design, technology, and digital fields, it is their goal to offer an integrated service for applications in automotive, electronics, furniture, lighting among other markets. The agency’s combined competencies allow them to work together, gather their skills, and tackle in detail every aspect in the conception of a qualitative product.KIT Lighting is one of their latest creatures, which made us decide to take a deeper dive into FutureWave.
FutureWave: Crafting Unique Experiences
FutureWave tightly combines designers and engineers to craft unique experiences. From the initial idea to final production of the parts, the agency focuses on the design and development of its products on innovation, aesthetics, interactions and performances by coupling designers and engineers over the whole process. KNIT Lighting is one of their latest concepts, fully produced by using advanced 3D printing technologies.
KNIT Lighting: Designed to Build Emotions
The KNIT lighting solution is made out of recycled PET. The closed-loop shape of this light is meant to work in correlation with 3D printing. The structure of the object follows a “vase-mode” process in order to print continuously without interruption. This process saves time and energy. The organic and soft curves of the light are in contrast with repetitive perpendicular stratification lines marked by the printer, which play a role in the refraction of the light. The process is part of the aesthetic language of the object and manifests the importance attached to its materials.
Design Approaches for innovative Technologies
According to Joachim Froment, Co-Founder of the agency and designer of ‘KNIT Lighting’, it was quite a challenge to design the Knit lighting because the idea was to deform the linear LED source into a more organic curve. Around this project, the main concept was to play around with the refraction of the light.
Froment loved to see how the light vibrates in traditional chandeliers made in crystal. So, he was wondering if it was possible to use recycled plastic and new 3D printing technologies to reproduce a contemporary version of the same principle of light refraction. Initially, he found it was nearly impossible. It was rather an instinct, a dream combined with some material and technology understandings. But it is through the making and the ongoing experiments that eventually it happened to become a physical product. Products communicate stories starting in the early process of the making, which is very important to consider when designing for a new lighting concept.
It’s not Silicon Valley and it’s not a collection of boffins in a “think-tank’, but in a light industrial precinct of Thomastown, one company may be changing the future of a worldwide industry:Limelite – an Australia based company, fabricates the next-generation light fixtures at the inhouse ‘Limelite 3D Printing Hub’. At 3DPrinting.Lighting, we’ve got some deep and exclusive insights in Limelite’s activities and, in addition, we had the privilege to speak to Paul Hearne, Limelite’s CEO, and get his deeper outlooks in his philosophy regarding the future of advanced lighting manufacture.
From Traditional to Additive Manufacture
A couple of years ago Paul Hearne, the founder of Limelite, attended a seminar on 3D printing at the Swinburne University of Technology. All of a sudden, Paul realized the flexibility offered by additive technologies could help build more customized luminaires at a lower cost and with great added value, in contrast to having them fabricated in traditional ways.
What began as a premature discovery ended up in a restructuring of his company, including an expansion of his facilities and the appointment of a specialized internal design and manufacturing team. Ultimately, Limelite moved from a project lighting company advising end-users on the lighting solutions of their needs, to an advanced 3D manufacturing business in only a few short years. From ‘selling fixtures made by others’ to create their own range of ‘customized 3D printed luminaires’.
To make change happen, Paul and his design team – led by his Chief Designer Nigel Brockbank – launched a joint project with industrial designers working at Swinburne University. As a result, the ‘On Track’ lighting collection was born, the first lighting Limelite range that was almost entirely 3D printed. The ‘On Track’ range was designed for additive manufacturing from scratch. After the moment the first 3D printed Luminaires hit the market, Limelite started to expand its 3D printing operations. At the moment of writing, it includes the production of three collections of Luminaires along with custom-made jigs supporting Limelite’s traditional manufacturing plants.
The Limelite 3D Printing Hub: Future Proof and ready for (further) take off!
LimeLite 3D Printing Hub
The Limelite investment in their own 3D Printing Hub was intended to achieve a number of goals.
First, the aim was to expand its business into the decorative lighting market, while still offering the commercial smarts. To date, Limelite had experience in providing standardized lighting solutions for educational buildings and medical facilities. Decorative lighting was a different story because the Luminaires had to fit skillfully designed interiors of aged care, offices, schools, hotels or cafes. Apart from getting the design right, the traditional manufacturing costs in this field proved to be higher as the 3D printed decorative lighting range and now also offer a much greater variety.
Secondly, Paul and his team realized that through the application of 3D Printing technologies, Limelite would get access to a range of unique features and benefits that were not available through conventional fabrication, such as molding technology. This would add significant value for the company and its customer base. In the section here after, we break them down for you in more detail.
Finally, growing a ‘future-proof-company’ requires some serious ‘forward-thinking’. Paul and his team believe that the future of fabrication is vastly different from today. 3D Printing will change the way products are designed, fabricated and transported. Limelite is about the ‘localization’ of manufacturing. With their innovations in the advanced manufacture with 3D printing as a process, they aim to create “Point of difference” luminaires. Limelite has found a creative and scalable way of doing business, utilizing ‘Industry 4.0 Thinking’ with a just-in-time methodology.
3D Printing Benefits for LimeLite
By setting up the 3D Printing Hub, Limelite got access to a range of interesting benefits, that put them in a unique competitive edge in the lighting market. While allowing tremendous flexibility of design, 3D printing also gives the business a number of very practical benefits. Let’s breakdown some of the advantages they now have access to in relation to their business:
On-Demand Production: While injection molding is obviously faster, speed is not critical in decorative lighting. Making thousands of luminaires in a week rather than in a couple of months is easily possible, but then you are also forced to keep stock and pay for it. With 3D printing on-site, production is closely matched to demand. Limelite makes the luminaires after the orders come in. At the end of the day, using 3D printers for production is cheaper than injection molding, when tooling and storage costs are included.
EnhancedCustomization: Customization of Light Fittings. Customers buying Limelite luminaires can ask for slightly ‘tweaked’ designs. For example, if a luminaire has a visible heat sink at the back and the customer wants it covered, that’s easily doable with only a small design change. With traditional manufacturing technologies, they would have to pay for retooling just to make the housing longer to cover the heat sink. With 3D printing the design could be adjusted in a couple of hours and printed accordingly.
Easy Design Iterations: Absorbing and implementing new technologies that appear on the lighting market brings along challenges in design. To give an example: if a next-gen light sensor comes to the scene, and it needs to be incorporated in the design, integrating this new sensor would take weeks or months if it had to be done with injection molding. With 3D printers, we could integrate this sensor in days.
No Tooling/Inventory: In fact, Limelite has no costs for tooling and storage. Typically, both 3D printing and injection molding are used for production. Standardized parts, like the ones with which a pendant fixture that’s attached to a ceiling, are injection molded. Decorative elements that bring out a particular style of the lamp are 3D printed. For the initial one, dozens if not hundreds of parts need to be sourced, components for the latter one can be produced to demand.
No-post Processing Needed: At this point, Limelite does not use any post-processing for their 3D printed luminaires. They are happy with the quality of surfaces and consistency of the 3D printers, and decided to use the fine detail layering of the print process as a ‘design gift’. Currently, they see no reasons for post-processing the physical, but it is not to say it is not going to change in the future when further optimizations can be done or value can be added.
Shortened Cycle Times: With the 3D Printing Hub in house, it takes 3 days to go from a sketch to a functional luminaire. Roughly, Limelite’s Hub can produce roughly 20 fixtures a day. Typically, from the 30 available 3D printers, 20 are used for production while 10 are busy running new prototype lamps, jigs and components for conventional products. This baseload can be scaled up overnight to meet increased demand. Limelite has designed room in its Hub for over 150 printers, designing for the future.
Easy Assembly: Also, the assembly can be significantly eased. It’s possible for to produce parts that simply clip into each other so there is no need for using glues or screws to put them together. In the assembly, the entire process turned out to be quite cost-effective. Additionally, this can also reduce assembly fatigue on staff, improving workplace health and safety too.
Cost-Efficiency: Last but not least: 3D printers allow them to achieve designs that are difficult or downright impossible to achieve with injection molding technology. With the lack of storage and tooling costs, 3D printed lamps are price-competitive. Although added value remains the primary driver, having moderate pricing for exclusive products is a welcome additional benefit. It all helps Limelite to compete and win against low-priced imports while giving our customers unique designs and better quality in the bargain. A true win-win scenario!
Lighting a New Way Forward
There’s another factor at work at Limelite and that boils down to passion for the job. Limelite began as a family company operating out of a garage. When you do that, you simply have to love what you do or you won’t last long. Limelite wants everyone who works here to be excited about the future of this company. After all, it’s their employees’ future too, so they encourage people to learn and grow.
“We come to work each morning knowing we’re making a difference. I reckon that excites us all!”
The company is also adamant that no item bearing its brand will leave the factory without being thoroughly tested. It’s important that Limelite customers know what they’re getting – and that it works exactly the way it should. Every single light made is thoroughly tested – it’s another edge they have over the cheap imports.
Limelite is steadily growing as a manufacturer and marketer of 3D printed commercial and architectural lighting, and is one of the first of its kind in the world to recognize and harness the potential of 3D printing. According to Limelite CEO, Paul Hearne, the revolution has just begun.
Are you equipped for the next Lighting Revolution? The Lighting Research Center (LRC), conducting research and development activities in the application of 3D printing to lighting since 2015, is sharing the knowledge they gained to date in a six-week, interactive, online course on the application of 3D printing to the design, development, and manufacturing of lighting components and products. The LRC 3D Printing Course will begin on September 30, 2020, and will run through November 18, 2020.
The 3D Printing Revolution has Begun
Additive manufacturing (AM), more commonly known as 3D printing, is poised to revolutionize the lighting industry. The revolution has already begun with a handful of designers setting the pace and some OEM manufacturers now offering 3D-printed lighting fixtures to the commercial market, but it’s just a glimpse of what’s more to come. It is expected that 3D printing will offer many benefits in the manufacturing of components for lighting systems, including the fabrication of cost-effective unique parts that cannot be made using traditional manufacturing methods, such as differentiating custom optics, heatsinks and flexible PCB and fixture designs.
3D Printing Course for Lighting Professionals
The course brought to you in an online setting, will provide training in the application of 3D printing to the design, prototyping, and manufacturing of lighting system components, and give participants the knowledge and skills needed to begin applying this technology in their own companies.
The course is designed for professionals from the lighting, 3D printing, additive manufacturing, and related industries to understand the possibilities of 3D printing for lighting and to learn more about each industry’s needs and capabilities.
Luximprint, a leader in offering multi-market prototyping services for Printed Optics and Optographix based in The Netherlands and SilvaCo Optics, a renowned California based optics, sensors and components consulting practice announced this week the partnership they entered into for marketing Luximprint solutions in California. An interesting move that makes access to rapid prototyping services for custom optics easier in the Silicon Valley surroundings.Here’s the latest.
Printed LED Optics – Fast, Flexible and Cost-Effective
Rapid prototyping services for custom optics are an interesting approach for designers and engineers working with light. Thanks to the optical 3D printing process, a proprietary solution by Luximprint to generate custom optics, tailored parts are available in days, which enables a fast, flexible and cost-effective engineering job when it comes to the development and implementation of new high tech systems in multi-market applications.
The direct ‘CAD-to-Optic’ manufacturing process from Luximprint grows optical clarity parts additively, aiming to offer a novel approach to validate optics designs, justify mold-tooling investments, as well as to create inspirational and functional mock-ups for event and user demonstration.
Printed Optics Come to Sillicon Valley
By having SilvaCo appointed as a local sales agent, needs centering around optics and photonics applications can now easily be addressed, just in time. Peter Silva, Principal of SilvaCo, was raised and educated in Silicon Valley when the South Bay was more orchards than manufacturing and before there was high tech. SilvaCo will work diligently to help find a solution that can satisfy customers that are in search of fast, flexible and cost-effective solutions in custom optics and other 3D printed solutions as marketed by Luximprint.
Custom Optics in Days by SilvaCo Optics
Companies located at the US West Coast in search of rapid prototyping custom optics solutions are encouraged to contact SilvaCo to discuss their next projects and utilize the powerful benefits of optical 3D printing. With typical lead times of 5-10 business days and global delivery with local support, rapid availability of custom optics is now guaranteed!
After over two years of intense research & development, the Seattle based company ‘Lightart’ finally shared its new ‘Coil Collection’ with the world. An exciting, 3D printed series of new pendants created from upcycled waste. These distinct matte fixtures have a look and feel like pottery, spun and handcrafted. Unexpected from fixtures produced through additive manufacturing.
A Unique Merge of Design and Upcycled Materials Science
How can we make recycled content look as good as possible? This was the key question during the product development phase for LightArt’s founder Ryan Smith and his team: “This is where things started to get really challenging. When we first started, it did not look polished—it looked like what you might expect when you’re trying to turn garbage into something beautiful. But we kept following the promise of the process, and made something we’re so proud of.”
The new Coil Collection addresses a central question the industry is facing: What can we do with waste? The team worked with the engineering division of parent company 3form to figure out what the base material possibilities were, and pushed the boundaries in collaboration with other polymer companies across the US to tap into collective expertise and drive for innovation.
Upcycling Plastic into Pendants: The Coil Collection
LightArt’s Coil Collection is made from internal waste material, but the brand hopes to expand the practice throughout the industry over time, as the LightArt facility strives to become a manufacturer of goods that are net positive in climate, waste, and energy.
Visually Appealing Content, Curvatures and Distinct Geometries
The design team of LightArt aimed for recognized classic pendant shapes focused on distinct geometry and curvature with a matte finish, giving the fixtures a pottery-like quality. The textured finish, inherent to the additive manufacturing process, is complemented by subtle algorithmic adjustments to achieve a handmade, one-of-a-kind feel.
The LightArt tdesignersfinally chose seven elegant shapes, deliberately defining the endless options afforded by additive manufacturing to create a curated product with a distinct LightArt feel. Departing from what is expected from a 3D printed item, the form is textured, tactile, and unique.
In design, recycling and sustainable innovation cannot be the sole drivers for innovation —the product has to be attractive, too. LightArt wanted the color and aesthetic of the Coil Collection to have a distinct value. Sorting the colors of the waste through new technology, the company came up with a monochrome black and white palette for the pendants.
We at 3DPrinting.Lighting will keep following LightArt with great interest and report upon the availability of new and sustainable concepts!
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