I began with a few initial sketches to determine a form I wanted to make.
After milling and cutting a Poplar board into 5 slabs (approximately 5.5"x11"x1"), I glued the boards together using wood glue and clamps.
After the glue had dried, I turned the block of wood using a lathe into the form I wanted.
After turning the block, I cut wooden form in half.
I then traced, cut and mounted an 3/4" MDF platform to the wooden form using screws.
Next, I vacuum formed 1/8" Styrene plastic over both halves of the wooden form to create two shells for my lamp.
I then cut away the leftover Styrene sheet close to the base of my form first using a Band Saw, and then trimed it flush with the top of the MDF platform using a Router Table.  I did this for both havles.
I then removed the shells from the wooden forms using pressurized air and by using a wedge and hammer. 
After removing both shells I bonded them together using a solvent bonding agent to create a complete shell form.
After the solvent had fully cured, I used a blade to remove any ridges.
I then proceeded to use a dremel to cut out the bottom of the lamp.
I smoothed out the edges of the cut using sandpaper, starting from a low grit and ending with a higher one.
I then added Bondo over the seams and wet sanded it to make it feel seamless. 
I spray painted the inside of the lamp first with a primer, and then with a matte black paint.
After priming the outside of the lamp and spraying a few coats of matte black paint, I added a few coats of high gloss spray paint.
Lamp Design
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Lamp Design

A lamp shade I designed and manufactured using Poplar wood, a wood lathe, Styrene plastic, a vacuum former, and spray paint.
6
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Published: