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lithopane lamp with rotating shade - white polycarbonate

by:Cailong     2019-08-09
lithopane lamp with rotating shade  -  white polycarbonate
I am no stranger to teaching, but I am more inclined to observe all the great thoughts than the ones that are now.
However, how can I refuse once I find the ShopBot challenge-this is definitely a game that I am very interested in!
The project I would like to share is a custom designed litecoane lamp with rotating shadows.
To maintain the spirit of the instrutables, this is a project where anyone can use basic wood shop tools such as: table saw, reel saw, router and some basic hand tools to complete the project.
I went one step further and showed how cool the CNC router is-I don't have a CNC router with almost the same functionality as the ShopBot.
My router is at best just a worn, low-tolerance entry-level router with 12 "x 18" tables, Rotozip of the spindle and powered by the HobbyCNC controller.
The software I use is borrowed from my work (
After a few hours, of course)
Is SolidWorks for design and BobCAD?
We use the cam for designing and manufacturing assembly fixtures for network products.
I don't work in the wood industry, but I do like to use wood as a hobby.
If I am lucky enough to win the ShopBot and AutoCAD software, I would like to design and manufacture larger carpentry works such as kinetic energy sculptures and clocks
Most moving wooden components.
The design of the lamp contains several 2D and 3D functions of the CNC software. Bobart (
Art package in BobCad)allows tool-Path like V-
Carve and create stone lines from the drawing. Other tool-
Paths in Bobcad (such as profiles, pockets, and 3D profiles) are also used in this design, but as mentioned earlier, basic lights can be manufactured without a CNC router.
The lamp uses a fixed base, and the lampshade rotates slowly around the base, so it is easy to view the picture.
I expect to run a 6 RPM motor using a gear head in about 3 minutes and then slow down with a wooden gear to a ratio of about 16:1.
I have supplied full size drawings for all parts, although some of them may be too big for standard printers, so either you need to print at a local print shop, print a few sheets of paper and stick them together, or scale and reduce the size.
All the drawings are at the end of this manual, along with the STEP file for the entire assembly, which can be imported into most 3D CAD software.
The wood chosen for this project is fir-yes, 2x8 "and 2x10" building Wood.
Depending on where you want to display the lights, the various woods are rich.
Cheap soft wood, such as fir, multi-section pine and cedar, works well in the look of the country or country.
Poplar and clear pine are also good options, with a slightly higher price, and better quality wood such as oak, walnut and exotic can also be used if you are after elegance.
Given the time you spend in the workshop, don't let the initial cost scare you, especially if the wood is set up correctly.
Since I have a planing bed, the thickness of any material can be achieved, and all the parts of this item are made of "and" thickness, these thicknesses are available for some species in local home improvement shops.
As an alternative, plywood can also be used, the thickness is "and", with fir, oak, birch veneer, which is a more stable building material compared to other materials, so it may also be a better choice for some of you.
If you use plywood, there are very few cutting edges shown by the assembled lights, which can be hidden using veener edges.
The lid is made from laminated 4 pieces of 2x8 Wood.
The wood is made of a large piece of material that is bonded and clamped.
After drying, I cut the wood into an oversized length and width and planed it to 2 "high.
This thickness is not important, is the result of the maximum z-
The height my CNC router can handle.
I designed the top cover to fit into the fan blade, which I thought was cool, giving the impression that rotation was the result of the heat generated by the light.
In fact, the cover can be solid or a 2D spoke type pattern can be made using a rolling saw to let the light go out and create shadows when the room rotates.
Key dimensions (so to speak)
External dimensions as shown in the figure.
Assuming you don't have a way to make a pocket, the main difference you might want to merge is the "wall thickness" around the bottom of the part ".
To do this, you have the option to assemble the top cover directly to the top of the litecoane frame and, if required, cut the trim into an arc.
The top cover is not a structural component of the litecoane frame, so don't worry if you choose a simple installation.
To add a circular look to the top cover, use a manual plane and Sander to shape the wood.
There are 5 litypane frames and you don't need to create litypane to make your lights.
The purpose of the frame is to hold the translucent/diffuser material and let the light go out.
My frame is made for 2x10 fir planned to thick.
The wood is cut into length, and as you can see on your table, a 36 degree angle is cut on each side.
To make an oval opening, print the drawing and stick it to the surface of the wood and follow the lines using a rolling saw or similar tool to try to make all 5 frames.
Use "circle" on the router bit to create a circular surface of the ellipse.
To make the pocket on the back, you can remove the material with the router using the flat and edge rails.
If there is no edge guide, there is enough clearance to mount the diffuser material directly to the back of the frame.
I added one that contains some basic V-
Carve on the frame and give it more decoration. V-
Engraving is different from engraving using a 60 or 90 degree drill (typically)and the v-
The engraving software will increase the depth of the pocket area and reduce the depth of the line area.
The picture is a vector file, usually. dxf.
If you have the skills and don't have a CNC router, you can try carving or burning wood to create a decorative look, but it is certainly not necessary.
The framesupport (2 pcs)
Is a structure that helps keep the frame together and provides an accurate angle.
When fully assembled, the outer spacing of these frames is the same as the inner spacing of the frame.
Cut 5 edges with your table saw and cut the circle with your Rolling saw.
The motor and gear brackets are cut from the flat plate and mounted on two small rectangular columns.
The external dimensions of the installation are not important, however, the relationship between the holes is because they position the gears with each other.
The size of the rectangular column should be small to keep the inner shadow of the lamp at a minimum.
For the sake of simplicity, I assigned 3 large gears and 3 small gears with the same teeth and sizes.
The big gear is 15 teeth and the small gear is 6 teeth.
The ratio of the entire gear system starting from the motor is 15.
65 rotation of the motor to 1 rotation of the lampshade.
The actual scale and speed of the lamp rotation is not important.
I just want the light to spin slowly so you can view the picture without being distracted by the quick spin motion.
Print the drawings of the two gears and stick them to the thick wood material.
Plywood is better than solid wood because the gears are made with a roller saw, and the Baltic birch is unlikely to fragment.
This is not a problem for a CNC router.
I found that the ball head vertical mill with 2 slots is small in depth ~ Step 0, can easily cut wooden gears in a variety of wood materials. 040” per pass.
No need to complete the pass (or wanted)
Because the end pass will end-
Due to the minimum retention of the wood grain support structure, the gear teeth are tilted upwards.
Note: I placed a plastic insert with a diameter of 1/2 in 5 of the 6 gears.
One of the 6 tooth gears has a hole size of 3/16, so it can be rubbed and installed on the motor shaft of 5mm.
All others use bolts as axles.
My lithopanes was created using a feature in BobArt where an image was imported and BobArt converted the image into a 3D model. Sound simple? -it actually is.
As with everything, better results can be achieved by importing pictures into photoshop or similar software and cleaning them up a little bit.
The 3D feature is based on the color representing the height, White is the lowest feature, and black is the highest feature (
When the light passes through the translucent material, it passes more easily at the thinnest feature and is blocked more by the thickest feature, resulting in an illusion of depth).
For my lithopanes, I chose 0.
236 transparent white polycarbonate.
I have been told that the best material is Keli because it is harder than plastic and has a higher melting temperature.
Unfortunately, the size I want is very expensive and hard to find.
The "Photo" I use is displayed in the photo below, I am in-
Align and crop them using the oval shape of the Litho frame opening.
Of course, they can also be real pictures, these are someone's paintings, but they are the approximate shapes I need.
I use 0 to process polycarbonate.
062 "carbide ball-
Milland sets the maximum machining depth when programming a rough machining to 0. 130" with a 0.
02 "stepover and 45-degree glyphs
Through the zag corner of the material.
With the same bit, I set the finish to max depth 0. 160" with a 0.
010 "stepover and 45 degrees zig-
Zigzag material.
To make litho look more perfect, I carved an oval around the picture with a 1/4 ballmill, 0. 170" deep.
Like FYI, there are several software brands that can do lithopanes.
A cheaper "stand-alone" program is made by Vectric called "PhotoVCarve.
You can download a demo and try it yourself.
Even if you don't have a cnc router, it will display an image showing the final machined part. .
The spindle can be done or bought.
I found my spindle in the curtain bar area of the hardware store, there are a lot to choose from, especially if you are going to paint your lights as there are a few of them are plastic, it is intended to be painted as a lamp that matches the home.
The rest are simple, and hope is self-explanatory.
Nothing special here.
Please refer to the pictures and drawings below to see the dimensions and other details.
The drawings are in pdf format.
You should be able to download. A bill-of-
The materials are also included below.
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