Introduction: George Mark Children's House Lamp
We designed a lamp with 3D printed lithophane shades and a laser-cut frame that families can fully customize with meaningful images and patterns, serving as a memorial to the young patients at George Mark Children's House. It will be designed for the patients and their families to make together utilizing the resources available in George Mark Children's House's maker space, with clear instructions and resources for the staff at George Mark Children's House to integrate the project.
Supplies
- 1/8in Thick Wood Stock for laser cutting
- White 3D Printer Filament
- Wood Glue or Super Glue
Tools:
- Glowforge Laser Cutter
- Ultimaker S5 3D Printer
Step 1: Designing the Lithophane Files
1. Start on Adobe Illustrator and invert the images (up to 3) you would like to turn into a lithophane.
2. Go to https://3dp.rocks/lithophane/
3. Insert your file and generate a flat lithophane.
4. Download the .obj file from the website and import it into Fusion 360.
5. Scale the model so the lithophane has the dimensions of 3.5in by 5in or smaller.
6. Extrude the flat sides of the lithophane so the overall dimensions are 7.5in by 4.15in. This is to ensure that the lithophane will fit snug in the lamp base.
7. Export the finished object from Fusion 360 as a .stl file.
Step 2: 3D Print!
1. Start by changing the filament to a White PLA filament using Ultimaker's built-in wizard.
2. Import the .stl file into Ultimaker Cura. (Check the object dimensions! If the object is extremely small, scale the object by a factor of 2450% using the scale tool.)
3. Make sure the material settings are correct for the filament loaded.
4. Slice the file setting the infill to 100%. Select ultrafine detail: 0.06mm. No supports. With the bed adhesion setting ticked. (The screenshot above shows the print settings.)
5. Export the generated .gocde onto a removable drive or send the print directly to the printer.
6. Start the print on the Ultimaker S5 and wait for the print to finish.
7. After it's finished printing, remove the lithophane from the build plate and admire it with a flashlight behind it!
8. Repeat for any other lithophanes needed.
Step 3: Getting the Illustrator Files Ready and Laser Cutting
1. Open up the template Adobe Illustrator File. Download the file below!
2. Import any patterns or designs you want into Illustrator. Place any designs into the spaces between the red cut lines.
3. Any images that are shaded black and white will be rasterized onto the wood you cut so your imagination is your limit.
4. Export the file as a .svg file.
Attachments
Step 4: Laser Cutting
1. Import the .svg file into the Glowforge software.
2. Set the material to the wood that you will be working with.
3. Place the file in an area it will fit inside of the Glowforge UI.
4. It may take some trial and error to get the best results possible. The important thing to remember is that when speed is decreased or power is increased the laser will cut/engrave deeper. When speed is increased or the power is decreased the laser will cut/engrave shallower.
5. If the images or pattern is not showing up as well, try reducing the speed of the laser, increasing the power, increasing the number of passes, or any combination of the three. Do the opposite if the pattern or image is too dark.
6. Make sure the outer lines are set to cutting lines to ensure the panels are cut out. If they don't cut out on the first try, DON'T MOVE THE STOCK. Try cutting again with just the cut path in the exact same spot.
7. Remove the material from the cutting bed and try a test fit!
Step 5: Assembly
1. Get every wood piece lined up on a clear surface.
2. Brush wood glue onto the sides of the box and start assembling the pieces like a lego. We recommend starting with the tall sides of the box.
3. Don't forget to add in the middle platform!
4. Clamp the project together and wait for the glue to dry.
5. Remove the clamps and place the lightbulb base in the center threading the wire through the hole in the back.
6. Place the lithophanes into the sides. They should fit into the holes on the base of the platform.
7. Turn off the lights and look at the glowing lithophane panels!