Solid Ash Lighting Prototype: From Design to Machining

For a design competition, Alcyde was recently asked to manufacture a lighting prototype for the designer francois_kessler. The material chosen for this piece was solid ash, appreciated for its strength and visual appeal. The objective of this project was to meet strong aesthetic requirements while integrating specific technical constraints.

The constraints of the specifications

The design of this designer piece involved several challenges when moving to production:

• Double-sided machining: The geometry of the part required turning it over on our CNC machining center. Holding and locating had to be precise to ensure the continuity of the curves and avoid any offset between the two faces.

• Internal cable routing: To preserve the aesthetics of the luminaire, the integration of electrical components had to be invisible. We machined internal channels directly into the mass of the ash, while ensuring the integrity of the structure was maintained.

• Flawless finishing state: Being a competition piece, the prototype required a high level of visual quality. Machining had to produce a clean surface, ready for sanding and finish application, without visible tool marks.

Technical realization

To meet these demands, the Alcyde team relied on its expertise in wood machining. The programming (CAM) made it possible to anticipate the management of the turnover and the creation of internal cable passages right from the modeling stage.

Custom-made holding jigs were used to stabilize the ash piece during milling. The choice of cutting tools and feed rates was adapted to respect the wood fibers and obtain the expected surface finish right out of the machine.

Conclusion

This project shows how CNC machining can bring concepts from industrial design to life. Through rigorous technical preparation, functional constraints, such as cable routing, can be integrated directly into solid wood, thus offering great creative freedom to designers.

Photos: Francois_kessler