The client designed a suite of lights with cast brass bases, folded sheet metal brass shades, and frosted enclosed glass shades.

To arrive at the final brass shade shape, I made prototypes from paper and aluminum sheet metal, then traced the approved shapes in SolidWorks.

The glass required custom external threads that would also allow a shoulder to accept a square-profile gasket to make them waterproof.

Final Sconce - Illuminated

Final Sconce

Dimensioned client sketch

Various Shade and Base prototypes

Sample Bases and Shade Prototypes

Final Bollard Light

Final Bollard Light - Illuminated

Client sketch with dimensions

Client Sketch

Prototyping process for Shades, Bases, and Glass

Aluminum, Brass, and thin Steel Bar Base Prototypes

Early Aluminum Shade prototype to identify hole locations

Handwritten edits to Shade

Shade First Article with not-yet-defined hole locations

Clamped-down aluminum Shade prototype to locate corresponding tapped holes in Base

Figuring out hole locations to mate Shade to Base

Prototyped aluminum Bases to confirm glass threading and water-tightness

Glass Shade samples: Externally sandblasted, internally acid etched, and clear

Tool/Form to properly shape the folded-over section of Brass Shade

Form inside folded Brass Shade

Hammering Shade over Form

Testing several hole locations to find optimal rivet hole locations

Final Pendant

Detail shot of Glass Shade in Base and riveted Shade support

Top view of Glass Shade projecting through Brass Shade

Client sketch of Pendant with dimensions

Approved aluminum sheet metal prototype

Two aluminum Sheet Metal Shade prototypes side by side

Flattened approved Shade prototype

Another flattened Shade prototype

Austin Resort Lighting Project

Angel Chandelier