// Other  ·  02

Airfoil Lamp

Light Diffusion Through Ribbed Airfoil Geometry — Preparing for Polished Aluminum Production

Year 2026
Category Other  ·  Product Design
Current Material Wood (Prototype)
Production Material Polished Aluminum  ·  1/8"
Fabrication Laser Cut — Boss Laser HP3655  ·  155W
Status Final Design Stage  ·  Pre-Production
Airfoil Lamp — Test Fit
// Prototype Test Fit Wood prototype test fit — preparing for polished aluminum production  ·  2026
// Overview

A lamp designed to diffuse light through a ribbed airfoil geometry — the internal profile of an airfoil cross-section reflects and distributes light through the structural ribbing, creating a layered, dynamic lighting effect.

Currently in the final design stage with a wood prototype used to validate geometry, rib spacing, and light diffusion behavior. Part files are being prepared for production in 1/8" polished aluminum, to be laser cut on a Boss Laser HP3655 155W engraver.

The transition from wood to polished aluminum will dramatically change the light behavior — from warm diffusion to sharp internal reflections characteristic of a polished metal interior.

// Key Specifications

Design Inspiration Airfoil Cross-Section
Current Material Wood (Prototype)
Production Material Polished Aluminum  ·  1/8"
Fabrication Method Laser Cut
Machine Boss Laser HP3655  ·  155W
Status Final Design  ·  Pre-Production
Interactive Model Available below
// 3D Asset

Lamp Assembly

LOADING MODEL...
LAMP INTENSITY 2.0

Lamp Assembly — SolidWorks Model

// Build Log

Build Log

Phase 01

Concept & Design Intent

Developed the lamp concept around the internal geometry of an airfoil cross-section. The ribbing structure that defines an airfoil's shape was adapted to serve as both the structural and aesthetic element of the lamp — diffusing and reflecting light through each rib.

→ Defined airfoil cross-section as design language
→ Studied light diffusion through ribbed geometry
→ Established design intent — diffuse and reflect
→ Began concept modeling in SolidWorks
Phase 02

SolidWorks Modeling

Modeled the full lamp assembly in SolidWorks — including the airfoil profile, rib spacing, base, and internal light housing. Geometry optimized for laser cutting in sheet material.

→ Modeled airfoil profile and rib geometry
→ Designed internal light housing and base
→ Optimized all geometry for laser cut production
→ Created full assembly with part files
Phase 03

Wood Prototype

Laser cut wood prototype on the Boss Laser HP3655 155W to validate geometry, rib spacing, assembly fit, and light diffusion behavior before committing to aluminum production.

→ Prepared part files for Boss Laser HP3655  ·  155W
→ Laser cut wood prototype parts
→ Assembled and test fitted all components
→ Evaluated light diffusion through wood ribbing
→ Documented geometry refinements needed
Phase 04In Progress

Final Design & Pre-Production

Incorporating lessons from the wood prototype into the final SolidWorks part files. Preparing production- ready files for laser cutting in 1/8" polished aluminum. The polished aluminum interior will create sharp internal reflections — a significant upgrade from the warm diffusion of the wood prototype.

→ Refining geometry based on prototype findings
→ Preparing production part files for aluminum
→ Specifying 1/8" polished aluminum material
→ Finalizing laser cut parameters for Boss HP3655
→ [Production run pending]
// Gallery

Build Documentation

Prototype Test Fit

Prototype Test Fit

Wood prototype assembled and test fitted to validate geometry, rib spacing, and light diffusion behavior.

Laser Cutting

Laser Cutting

Parts being cut on the Boss Laser HP3655 155W laser cutter/engraver.

// Skills

Skills Demonstrated

Design

Product Design Airfoil Geometry Application Light Diffusion Design SolidWorks Assembly Modeling Design for Laser Cutting

Fabrication

Laser Cutting — Boss HP3655 155W Wood Prototyping Sheet Metal Design — 1/8" Aluminum Part File Preparation Assembly Fit Validation

Process

Concept to Prototype Iterative Design Material Transition Planning Production Preparation 3D Model Visualization