How will 3D printing affect my business? This question is being asked by companies in several industries, especially those involved in the manufacturing process. A diverse group of companies came together last month to discuss and better understand the impact of 3D printing in the lighting industry. 3D printing, also known as additive manufacturing, is already being used in several industries to augment conventional manufacturing.
3D Printing – Understanding the Impact on Lighting
The discovery workshop, organized by the Lighting Research Center (LRC) at Rensselaer in partnership with Carbon Group Global, was designed to understand the impact of 3D printing across all areas of buildings and construction, and especially its impact on lighting. A group of industry leaders focused on how to best assimilate 3D printing with the lighting industry, the mutual benefits to all stakeholders, and the implications to and the impact on the existing ecosystem. The group will soon embark on developing an industry roadmap to make additive manufacturing a viable option for the lighting, building, and construction industries.
The Benefits of 3D Printing for Lighting Professionals
The potential benefits of 3D printing include the ability for manufacturers to create custom products that are uniquely designed for spaces to be illuminated. Fixtures could be printed on-site and on-demand, benefitting the user/customer, the manufacturer, and the local construction industry.
3D Printing Individual Solid State Lighting Components
With 3D printing, the manufacture of individual lighting components, such as heat sinks, electrical traces, and led optics, could be customized, enabling the design of parts that cannot be manufactured today by traditional methods, improving both aesthetics and functionality.
Research is still needed to advance the integration of 3D printing into the lighting industry, beyond the current prototyping stage. To date, the Lighting Research Center has conducted initial investigations into the potential for printing thermal, electrical, and optical components.
A new, unconventional approach by Michigan University to 3D printing creates stunning results in an up to 100 times faster 3D Printing process. The newly invented methodology was recently reveiled and rather than building up plastic filaments layer-by-layer, it lifts complex geometrical shapes from a bath of liquid resin at up to 100 times faster 3D printing than conventional printing processes do. Here are some deeper insights.
3D Printing: A Game-Changer for Manufacturing
3D printing could potentially change the game for relatively small manufacturing jobs, producing < 10,000 identical parts. It would mean that the objects could be made without the need for a mould tool, coming with a significant upfront investment. But the most familiar forms of 3D printing, which are sort of like building 3D objects with a series of 1D lines, hasn’t been able to fill that gap on typical production timescales of a week or two. Scaling towards larger volumes has only been possible by multiple printers in parallel, each of them duplicating the same approach, what is not very efficient.
Printing Optics at Speed
As far as we are aware, it’s been thus far only the process of 3D printing optics, that has basically evolved from UV-inkjet printing, that can produce parts at such high speed and has the potential to scale to larger manufacturing quantities. This process, however, is fully tailored for additive fabrication of custom optics and Optographix and does not offer commercial solutions for other markets, as far as we are aware.
The Michigan University Approach
The Michigan University method solidifies the liquid resin using two lights to control where the resin cures – and where it stays liquid. This enables the team to solidify the resin in more sophisticated patterns. They can make a 3D bas-relief in a single shot rather than in a series of 1D lines or 2D cross-sections.
By creating a relatively large region where no solidification occurs, thicker resins – potentially with strengthening powder additives – can be used to produce more durable objects. The method also bests the structural integrity of filament 3D printing, as those objects have weak points at the interfaces between layers.
An earlier solution to the solidification-on-window problem was a window that lets oxygen through. The oxygen penetrates into the resin and halts the solidification near the window, leaving a film of fluid that will allow the newly printed surface to be pulled away.
But because this gap is only about as thick as a piece of transparent tape, the resin must be very runny to flow fast enough into the tiny gap between the newly solidified object and the window as the part is pulled up. This has limited vat printing to small, customized products that will be treated relatively gently, such as dental devices and shoe insoles.
By replacing the oxygen with a second light to halt solidification, the Michigan team can produce a much larger gap between the object and the window – millimeters thick – allowing the resin to flow in thousands of times faster.
The Resin: Key to Success
The key to success is – like in many other (3D) printing processes, the chemistry of the resin. In conventional printing systems, there is generally only one material reaction. A photoactivator hardens the resin wherever light shines. In the newly invented Michigan system, there is also a photoinhibitor, which responds to a different wavelength of light.
Rather than merely controlling solidification in a 2D plane, as current vat-printing techniques do, the Michigan team can pattern the two kinds of light to harden the resin at essentially any 3D place near the illumination window.
Soon, a research paper describing this approach will be published in Science Advances, titled, “Rapid, continuous additive manufacturing by volumetric polymerization inhibition patterning.”
As described before, the process invented by Michigan University reminds us very much about the invention of ‘Printoptical Technology’ (3D printed optics) by Luxexcel back in 2009. We are greatly interested to learn whether this novel approach would bring new approaches and/or synergies to the table, especially related to applications in the Lighting Industry. In any case, we will be following the developments around the innovation with great interest!
LPS 2018 Celebrates the Launch of Additive Fabrication Services for Custom Optics by Luximprint
“Additive Manufacturing Services for Functional and Decorative Optical Plastics Empower New Lighting System Design and Development”
Luximprint, a Dutch multi-market service provider for 3D printed optics, chose the 2018 LED professional Symposium and Expo as the springboard to launch its novel fabrication services for decorative and optical 3D printed plastics. Light engineering and design professionals in need for fast, flexible and cost-effective optics solutions can now take benefit of the unique advantages Additive Optics Manufacturing technology offers for new lighting system design and development.
LPS 2018: Springboard to the European Lighting Industry
Choosing ‘LED professional Symposium + Expo’ along with the co-located ‘Trends in Lighting’ event as a launching platform has been a strategic decision for Luximprint. Among the European Lighting events, LPS and TIL take a leading position in bringing the latest strategies related to new technologies and digitization closer to market professionals. It provides both engineers and designers of lighting systems a unique platform for new fixture development.
“Presence of digital manufacturing technologies is key, as it significantly contributes to improved system engineering and finally a healthier industry”.
Additive Optics Fabrication
Printed optics has come a long way in the lighting industry. Additive Optics Fabrication, marketed over the recent years by Luximprint, is a future-proof methodology of rapid prototyping custom LED optics by means of digital fabrication technologies. Direct ‘CAD-to-Optic’ manufacture avoids costly and uncertain commitments related to conventional optics manufacturing processes in the early development stages, such as upfront tooling investments and minimum order quantities.
Printed products find their way find their way in a variety of engineering and (temporary) project applications, such as general lighting, (light) art, event- and interior design. Luximprint solutions serve mainly inspirational and functional demonstration purposes, as well as mold-/concept validation and pre-series fabrication.
Optographix: Optical Translucency for Branding and Interior Design
In addition to functional optical plastics, so-called ‘Optographix’ – as the name suggests a unique combination of optical translucency and full-color graphical expressions – are initially proposed at this years’ events to trigger lighting and interior designers.
Optographix – compromised by full-color patterns and optical translucency – add value to artistry and design of spaces and are set to be a next method of translating a corporate or brand image by using a unique combination of 3D printing, optics and light.
Design for Additive Optics Fabrication
Educated and trained by Luximprint, the Luximprint ‘Optics Design Hub’ includes a network of affiliated optics designers through which Luximprint facilitates its users in designing for additive manufacture. Among them is Physionary, a Netherlands based optics design collective.
Listed for the 2018 LPS / TIL Award, Physionary provides a new revolutionary methodology for designers with light, enabling them to ‘put light where needed’. Physionary ‘Faceted Lens Technology’ greatly combines with Luximprint Additive Optics Fabrication Services as tailored lenses now can be made in a fast, flexible and cost-effective way. Above all, it provides anyone involved in the design and application of lighting systems with new tools for a more efficient and responsible use of light.
Luximprint shared a booth at LPS / TIL 2018 where it demonstrated its cooperative approach in additive optics design and manufacture for future lighting systems together with the team of Physionary.
At 3DPrinting.Lighting, we’re watching both Luximprint and Physionary with great interest!
Philips Lighting Telecaster: Philips New Venture for 3D Printed Architectural Lighting
Philips Lighting Telecaster is a new venture that is bringing the magic of 3D printing to architectural lighting. Initiated by Philips, the ‘print-on-demand’ technology and product configuration tools enable tailored custom lighting fixtures to be produced in new creative ways.
3D Printing by Philips Research
Telecaster is evolving from years of initial 3D printing exploration and development. Various digital manufacturing technologies were adopted and discovered by the Philips Research team in Eindhoven, Netherlands. Philips Research optimized various 3D-printing technologies that dramatically increase the speed and lower the cost of 3D printing, finally bringing it into the reach of their volume luminaire lines.
Exploring the Rich Possibilities of AM
Telecaster is a new internal venture team, that was tasked to commercialize those efforts and explore the rich possibilities inherent in digital additive manufacturing. Here, you can think of new 3D printing materials, different form factors, as well as mass-customization services for tailored products.
To date, Philips has developed numerous styles of fixtures: 3D-printed decorative pendants, track spots, downlights and even large highbay fixtures.
Complex Shape Geometry in Volumes
Users are able to select from expressive geometric shapes and new materials textures to create combinations truly unique to any project. Unlike other 3D printing technologies, Philips Lighting Telecaster technology is ready for volume applications today.
The new series includes various downlights, pendants and projectors in a stylish performance.
Philips Lighting Telecaster Pilot Projects
Philips Lighting has piloted its various 3D printing technologies today in several real-world installations. Here are a few examples:
1 of 3
Setting the Pace for Future Lighting Design and Development
It seems, Philips finally found a way of adopting 3D printing technology to change and grow its future lighting business from the inside.
We’re watching the interesting developments closely, hopefully there’s more news to launch soon!
3DCompare: Search Engine for the 3D Printing Industry
3DCompare launches the first professional comparison platform for 3D printing. Based in the UK, the portal matches companies in search for 3D printing solutions with verified, professional and established 3D printing service providers around the world. The Price Checker scans hundreds of 3D printing businessess and materials to help its users find the cheapest price for their prints.
3D Printing Market Development
Active in North America and Europe, 3DCompare is rapidly expanding these days into a global network. The growing demand for 3D printing asks for novel platforms and solutions to ease decision making of a broad offering. Experts estimate that, in 2020, the 3D market will grow to 28.9 billion US dollars, coming from a level of 13.2 billion in 2016. Industries such as automotive, architecture and dentistry have realised 3D printing potential for cheaper and better quality objects.
The 3DCompare database helps to select the best possible service for its users’ needs. Whether they want to compare prices, find out the shortest lead times, discover the best 3D Printing Materials, or learn about the shipping costs related to a particular job, any of 3D printing service providers listed in the portal is readily available to serve.
The team of 3D Compare is continuously extending its database in order to get the best offering for their users’ project. We’ll be watching it closely and we are sure there will be more news to be announced in the time to come!
Illuminate your Imagination: 100 Unique 3D Printed Lamps Installation by Budmen Industries
‘All of the Lights’ by Budmen Industries is an immersive light installation including 100 unique 3D printed lamps. It acts as a unified display of individualism. The project represents a bright future where individuality is celebrated and reflected in environments that are as unique and complex as we, human beings, are.
Hand-crafted Digital Designs
The All of Lights installation redefines 21st century craft by combining art sculpture and digital fabrication. To attach a personal and human element to each of the designs, the designers decided to digitally sculpt each lamp shade by hand.
Following the designers’ unique approach, a great variety of different shades was created, each reflecting unique personalities. Some were symmetrical and had a pure geometrical appearance, while others were more gestural, feeling like captured motion. Or they were swirled and stretched into splendid spirals.
3D Printing Large Luminous Layers
In fact, 3D printers can build hundreds of identical objects but their real strength is in making hundreds of different objects at no extra cost. 3D printing is a shift from a world full of mass manufactured products to one where each item can be a unique reflection of our individuality (called ‘mass customization‘)
A 3D printer creates objects layerwise. This process of stacking layers produces surfaces with striations similar to those seen on rock formations and tree bark. Printing with thick layers produces even more dramatic striations.
Illuminated Layers as Project Signature
Where for some applications the layering might be a limitation, the Budmen designers decided to see and use it as an charismatic feature of the process. The uniquely layered aesthetic is not only a process signature, but the object takes on an entirely new character when illuminated.
The Brains behind Budmen Industries
Budmen Industries was founded by Isaac Budmen and Stephanie Keefe. Budmen is an artist, designer and ‘lifelong inventor’ as he describes himself. His creative work exploring digital fabrication has been featured at leading museums and other venues.
Stephanie is an artist as well, pastry chef, and photographer. Her photographs have been exhibited and sold in NYC and Chicago. Together, they created Budmen Industries.
To celebrate the ‘All of the Lights’ project, Budmen released a special book on the immersive installation. Pre-order books are available for a special early-bird price, personalized and signed by the artists. Books will be shipped February 2018.
Repro-light Consortium aims to Revolutionize the Lighting Industry by 2020
As part of the Horizon 2020 programme, an European project for re-usable and re-configurable parts for sustainable LED based systems was initiated by lighting industry leaders. Named ‘Repro-light’, it aspires to successfully initiate a transformation in the European lighting industry, with the ultimate aim of creating the ‘Luminaire of the Future’. We thought it would be good to write a brief update on it, as it will significantly affect our future and inspire our readers!
Innovative Technologies and Materials
The Repro-light project harnesses innovative technologies and materials and aim to implement modular luminaire architecture as never attempted before. Called the ‘Luminaire of the Future’, it will include a smart production scheme and the development of a reconfigurable easily customizable LED luminaire.
Market Focus: From Energy into Function
The Repro-light project is perfectly timed to capitalize and lead this transformation. It is set to change the reputation of the LED luminaire from a disposable object, into a customizable and sustainable product, with a high function value. The LED market is currently mid-transformation, shifting its focus from energy efficiency to function values, therefore the timing of the project is perfect!
Consortium of EU Lighting Experts
Led by representatives and driving forces from the European lighting industry, as well as manufacturers, experts on lighting sustainability and the Social Sciences, the Repro-light consortium possesses the excellence and the influence to not only execute this project successfully, but also invoke a sustainable change in the European lighting industry beyond the lifetime of the project.
OEMs – Innovation leaders – Universities
The need for projects like Repro-light has been highlighted over the last years by leading lighting experts and institutions. Now, some of these thought-leaders join forces in the Repro-consortium. It includes several leading European manufacturers such as TRILUX, BJB, Ground Zero, and Rohner Engineering.
In addition, it contains remarkable innovative members of the lighting industry as Bartenbach and Luger Research, as well as experts on lighting sustainability and Life Cycle Assessment IREC and Mondragon University who are prominent in Social Sciences.
Market Needs and Requirements
The project’s first phase is underway. This initial phase of work will focus on analysing the customer needs and technical requirements. This information is vital for the following project stages, the initial phases finishing by March 2018.
Project Updates: Stay Tuned!
To receive updates on the project progress, to receive additional information about Repro-light or to learn about its partners, please visit the website.
We at 3DPrinting.Lighting strongly believe there is no future for the lighting industry without incorporating 3D printing in product design, development and operations, so we’ll be following the project updates with great interest and inform you once interesting developments come to pass. Stay tuned!
3D printing has changed how products are prototyped. With Gantri, it’s changing how products are made. The unique Gantri 3D printing process combines the simplicity and flexibility of desktop 3D printing with the quality and craftsmanship of industrial manufacturing. It allows designers worldwide to easily bring quality products to market at a fraction of the time and cost.
Gantri: Simplicity and Efficiency in Design and Fabrication
Gantri aims to break down the barriers in traditional ways of manufacturing and selling. Simplicity and efficiency are key in their designer approach. By promoting inspired design rather than a specific aesthetic, design becomes relevant to everydays life.
“Gantri helps independant designers to create inspired, high-quality lighting products and make them accessible and attainable for all”
Innovative Materials and Processess
Working with the best material innovators from around the world, we offer corn-based materials that are environmentally friendly, purposeful and durable. The in-depth knowledge of 3D printing allows designers to create optimized 3D models and achieve higher quality prints straight off the printers.
Every part is hand-finished and foreseen with a protective coating to achieve a perfect finish that feels comparable to traditional luxury products.
Bring your Concepts to Life
Gantri welcomes talented designers regardless of location or academic degree. Any independent designer around the globe can become a member of the Gantri Community to create his own products and brand.
Please refer to the Gantri shop to source your own table lights, created by independent designers worldwide. All products are made in California.
Korean Architect Creates stunning 3D Printed Trees for Temporary Art Installation
With a background in architecture, Korean designer Se Yoon Park recently created a stunning piece of art including 3D printed trees. Contrasting influences his former rural life, made him develop an interest in issues such as light, darkness, time, and life. Experimenting with gradient light and its consequent shadows, Se Yoon arrived at this particular form for his 3D printed trees, where the play of light produces ever-changing effects.
Light, Darkness and the Tree
The project ‘Light, Darkness and the Tree’ is the result of the contemplation of the words that Park takes most seriously: light, darkness, time, and life. His work explores the transitions between light and darkness, and in his sculptures, he seeks to contain both light and darkness within an exterior, a single object. His creature consists of many smaller geometric elements and imitates the organic structure of a tree.
From ‘Concept’ to ‘Design’ to ‘Reality’
The initial design stage knew multiple media, from hand-written sketches, to handmade models, to digital 3D models in Rhino. All the parts were designed in Rhino for production on a 3D printer. The biggest challenge has been error control in retaining an accuracy in shape that was essential for the structural integrity of the overall artwork.
Advantages of 3D Printing Technology
Compared to traditional methods where material is casted away, the additive 3D printing process allows being more accurate, and it is free from shrinking issues. Moreover, it provides to work with multiple design materials and bring them together in one build.
Also, a the combination of traditional fabrication methods and 3D printing technologies might be a way forward. 3D printing is a very helpful way to rapidly turn ideas into reality, while the more mature conventional technologies can turn them into real production items.
Light and Darkness in a Sculpture
Se Yoon chose Polyamide material for his creature due to its strength, lightness, and porosity, which allowed him to structurally employ the 3D printed parts in his sculptures. It also gave him the flexibility of dyeing the pieces to explore a variety of artistic surface treatments. The translucency of Polyamide also allowed him to play with an electrical light inside his sculptures, creating the effect of a soft glow.
3D Printed Trees – The Making Of: Polyamide Materials and SLS 3D Printing
Polyamide is 3D print material that is used in combination with a process named Selective Laser Sintering (SLS). Laser Sintering 3D printers do not use a filament, as many DIY printers do. On the contrary, a very fine, granular nylon powder is heated and sintered by a laser beam within the 3D printer to create the parts.
Award Winning Centerpiece Electric Light Shoe by Janne Kyttanen merges Japanese Culture Icons
The Electric Light Shoe is a 70 centimeters tall sculpture containing a dream-like universe. The artwork features a kaleidoscope of Japanese cultural icons and was designed and fabricated back in 2008 already by designer and artist Janne Kyttanen. The illuminated shoe was created as the centrepiece of the award winning Onitsuka Tiger global Electric Tiger Land campaign.
Electric Light Shoe: A Living Glowing Sculpture
The super detailed structure is laced with an LED lighting system that glows and pulses, bringing the sculpture to life. There are only one eight sculptures available in this super limited edition collection, plus two artist proofs.
The Onitsuka Tiger – Symbol for Streets and Highways
The characteristic Onitsuka Tiger stripes represents a system of highways and streets. Illuminated signs crowd the front of the shoe and a monster-like figure looms over buildings at the shoe’s opening.
Janne Kyttanen is a pioneering digital sculptor creating multidisciplinary work at the intersection of 3D printing, virtual reality and augmented reality. His work has been featured in TIME Magazine’s ‘Design 100’, the people and ideas behind the world’s most influential design. Kyttanen is best known for his revolutionary work with 3D printing and is considered to be one of the most influential designers of his generation.
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