By Rajat Bhayana
The world of lighting design is undergoing a transformative shift thanks to the advent of 3-D printing technology (also known as additive manufacturing). This innovative technique is empowering designers to overcome traditional manufacturing limitations.
The words “3-D printing” may evoke different thoughts depending on personal experience, but the leaders in 3-D-printed luminaire manufacturing are invested in advancing the techniques from laboratory scale to industrial production. The advantages associated with 3-D printing overcome many common customer issues, including inflexible customization options, difficulty meeting sustainability goals, inconsistent product quality, long lead times, and unreliable delivery. While traditional manufacturing technology typically addresses at least one or two of these problems, the true value of 3-D-printed luminaires is their ability to offer customers a combination of all these benefits.
Performance is likely the highest priority for any commercial-grade architectural luminaire. 3-D-printed luminaires deliver a high-performance portfolio with specification-grade light engines, superior color rendering, high efficacy, ranges of lumens, low maintenance, and long life. Additionally, they can be personalized with an assortment of in-stock and on-demand colors, textures, and shapes for virtually unlimited design possibilities.
Perhaps most impressive is the speed with which 3-D printing can fulfill an order, end-to-end. The process of designing, customizing, manufacturing, and delivering 3-D-printed lighting can take just a fraction of the time required for traditional manufacturing processes. For example, Cooper Lighting Solutions was awarded a project for AutoStore, the world leader in robotic lighting, after a traditional manufacturer could not meet the client’s tight deadline for customized lighting. By utilizing 3-D printing capabilities, AutoStore’s concept was transformed into reality within just 10 days.
Sustainability is a growing concern in the lighting industry, and 3-D printing offers opportunities to reduce waste, energy consumption, and a manufacturer’s carbon footprint. The additive manufacturing process inherently reduces material waste compared to traditional subtractive manufacturing methods, and 3-D printing makes it possible to manufacture only the necessary components for each project, minimizing inventory waste and the need to warehouse luminaires for future use. Each 3-D project’s information is stored digitally, so if more of a particular luminaire is needed, manufacturing them using 3-D printing is much faster and easier than traditional methods. Lighting manufacturers that have access to multiple 3-D print hubs located throughout North America can also enable localized manufacturing, resulting in a significant reduction in transportation emissions.
Additionally, additive manufacturing can create lightweight and energy-efficient luminaires. The recycled or mass-balanced, bio-circular plastics often used as filament enable durable, lightweight luminaires that can be easily installed.
But how does the technology measure up in combining functionality and aesthetics for wide-ranging applications? In high-end retail environments, 3-D-printed luminaires can create immersive and visually stunning retail experiences. Imagine captivating “Winter Wonderland” displays replicating the illusion of ice and snow using translucent materials that allow for a dynamic interplay of light and movement. These types of fixtures can also reinforce a brand’s identity and create unique shopping environments using colors, textures, and shapes.
Custom 3-D-printed pendants in metallic golds and silvers can elevate the ambiance of hospitality spaces, adding a touch of elegance and warmth to areas such as hotel lobbies, restaurants, and waiting areas. Interactive installations can be employed that create dynamic lighting experiences that respond to the environment or user input can be augmented with 3-D-printed lighting.
In general, the technology can create intricate luminaires that enhance façades, atriums, and other public spaces. Unique focal points can be created, where custom, 3-D-printed chandeliers, wall sconces, and table lamps exude luxury and sophistication.
As with most new technologies, there’s room for improvement, starting with the materials used to create 3-D-printed luminaires. While popular materials like resin and nylon allow for creative designs, they don’t always hold up well over time—especially when they are exposed to heat. To avoid this pitfall, look for 3-D-printed luminaires that are made of stronger, more-heat-resistant materials such as mass-balanced, bio-circular plastics.
Another challenge for some companies offering 3-D-printed lighting involves large-scale production. If an additive manufacturer doesn’t have access to multiple print hubs nationally or globally, chances are that printing in bulk with such a company would take more time compared to traditional methods. If time is of the essence, designers should consider working with lighting manufacturers that have the tools, resources, and capabilities to print luminaires quickly and efficiently.
To ensure the successful implementation of current 3-D-printed lighting solutions, designers should consider the following best practices:
Prioritize sustainability by choosing environmentally friendly materials and energy-efficient lighting sources. Look for the Declare label for an extra measure of assurance about the health and environmental impact of a 3-D-printed product.
Use the customization benefits of additive manufacturing to design luminaires that are easy to install and maintain.
Ask for samples from your additive manufacturer. Conduct rigorous testing to ensure the durability and performance of 3-D-printed components.
Embrace innovation. Learn about the latest advancements in 3-D printing technology.
From personalized home lighting to large-scale architectural installations, the potential applications for 3-D-printed lighting are limitless. The growth of additive manufacturing of lighting in the U.S. has been gradual and is expected to accelerate its upward trajectory as knowledge of its capabilities becomes more widespread.
The future holds promise for the development of new materials with enhanced properties. Technological advancements will likely lead to increased production speed and reduced costs. Additive manufacturing will continue to focus on enhanced sustainability with more eco-friendly materials and processes.
THE AUTHOR | Rajat Bhayana, product manager at Cooper Lighting Solutions, has more than 13 years of industry experience, including over 8 years in lighting product development. He specializes in guiding products from concept to completion and is passionate about driving innovation in the lighting industry.