Full scale production on the Matchstick Light has started. Two out of 28 have been produced, with the remaining 26 to be completed by mid-December.
Nov 172011
May 032011
The Matchstick Light started as a fun little side project – a distraction from thesis doldrums. It soon became part of my thesis, and what was once a little side project ballooned in to the most complex project I have ever undertaken. I was inspired by the simple, clean lines of dimensional lumber. I was fascinated by the possibility of having a bright, usable light coming from an unexpected form and material – namely 3/4″ sticks of maple. High quality stainless steel machine screws and wing nuts complete the utilitarian aesthetic, while the red cord and red stained dimmer at the tip of the light suggest further purpose and inner power.
The red cube serves as the switch and dimmer.
The simple outer form hides the complexities of the manufacturing. Each light is milled from one solid maple blank. The sticks of maple are actually comprised of two separate halves, with all components and wiring sealed inside. I designed the overall form, machined the wood components, and did final assembly. I was helped by Zack Shivers, an electrical engineer and friend, who designed and assembled the circuitry. I knew I would be assembling all of the lights by hand on my own, so I strove to create internals that were as simple and elegant as the exterior. I worked closely with Zack to tackle the challenge of thermal management, and we were able to devise a solution which should allow around 50,000 hours of LED life.
Academically, the light is an exploration of how a CNC mill can expand and enhance the capabilities of the maker; allowing them to create something that would be impossible, or at least unreasonable, to create entirely by hand. You can get some insight in to the process in some of my past blog posts.
Details and Ordering:
- Warm white LED lights – 3500K – 85 CRI
- 640 lumens – dims from 25% to 100%
- High efficiency – 6 Watts at maximum brightness
- Greater than 50,000 hours estimated lifetime
The Matchstick Light is being manufactured as a limited run of 28, each individually numbered. They will be available through the Kivi Did Etsy page when they are completed some time in early December.
Apr 222011
About a year ago I had the opportunity to do a small project with Zeke Leonard, a professor in the design department, and Hallie Verrier, a fellow student. A building in downtown Syracuse was being renovated, and a number of 100 year old long leaf pine structural beams were being removed. We were asked to take the beams and turn them into seating for the soon to be completed building.
We were able to take the beams and the original mounting hardware and make a pair of benches using only original materials.
Mar 162011
Mar 162011
Timelapse of the LED test I did here.
Mar 152011
Mar 132011
The Matchstick light is coming along. To get the best deal on the circuit boards, we have to order 30 boards. We probably won’t be making 30 lights, but we will be making (and selling) as many as possible.
Changing the thumb nuts to wing nuts is saving a ton of money. The thumb nuts cost over $5 each. The wing nuts tighten much better, are far more ergonomic, and only cost $0.75 each. I also think they go with the dimensional lumber style of the whole thing.
Made a mock up of the light for heat testing with a SparkFun breakout of our LEDs. I milled the test stick for the two LEDs I ordered, but one of them broke the moment I took it out of the packaging. Hopefully I’ll be getting a replacement soon. The final light will have eight of these LEDs on a dimmer.
Mar 112011
Feb 282011
Feb 222011
I was asked to make a bowl for the Prosthetic Outreach Foundation Gala auction. Primarily made of mahogany with a quilted maple insert as a prosthesis.
Making of video coming soon.
