Bent Lamination Lamp

I have been experimenting with bent lamination and have seen examples where the individual layers converge and diverge in the final form. I designed this lamp to experiment with that concept, and think the result is pretty cool. There are lots of ways this project could be modified and customized when you try it yourself!

• 3/4 plywood to create the form
• 1/16 inch thick veneers for the body of the lamp.
• I used these veneer sheet from Roarockit.
• Material for the lamp base. I used a piece of walnut.
• Pendant Light Fixture. I wired my own with components from the Color Cord Company
• Keyed Socket
• Plug End
• Cloth Covered Cord
• Miscellaneous hardware for cord stay.
• Or this one would be cool

Create the form

The form is created from three layers of 3/4 inch plywood. It is a semi circle with a 17 inch diameter, and two extensions added. Wholes are drilled with a forstner bit to allow for clamps. You could also use band clamps, or ratchet straps to clamp the veneers.

Prepare the form by taping the outside edge with packing tape to keep glue from sticking to it.

Preparing the Veneers

8 strips 30 inches long and 2 inches wide are ripped on the table saw or bandsaw. The strips are about 1/4 inch wider than the desired final dimension to allow for the edges to be cleaned up after glue up.

Glue Up

Strips will be glued up in pairs all at the same time for a more efficient glue up.

Spread the glue on one strip of each pair and then clamp to the form.

Clean Up the Edges

After removing the strips from the form clean up the edges first. I ran them through the table saw, but you could hand plane them, or sand them smooth. The final width of each strip is about 1 5/8 inches. The actual width is not important as long as it can accommodate the lamp parts.

Sand the Faces

I then used a random orbital sander to sand both faces. Each strip is flexible enough to do this with a power sander, but your could also do it by hand.

Mockup The Final Shape

I then clamped the strips together to mockup the final shape. I played with the locations of the clamps and the space between each strip. At the base, the strips are separated by 3/4 inches. Once I was happy with the shape I marked where the ends would be glue, and where the strips will meet the base.

I used a miter saw to cut the ends to length where they will mount to the base. Each strip has to be cut to length individually now, because it would be too cumbersome once they are attached to each other.

Pre Finish

Using the reference marks I made above I prefinished the strips. I did not apply finish to the areas that will be glued. Pre finishing now is easier than trying to apply a finish once it is glued up.

Final Glue

Glue the strips together.

Final Shape

After the glue dried I cut the top of the lamp to final length and sanded a curved profile at the end.

Hole for Socket

The socket from the Color Cord Company has a diameter of 1.286 inches. You could drill with a 1.25 inch forstner bit and then enlarge the hole with sandpaper. I chose to use the CNC machine to cut a whole of the precise diameter.

Sand & Finish

I then did a final sanding and applied finish to all unfinished areas.

The lamp will attach to the base in four slots cut to accommodate the ends of the strips. I originally created a base out of plywood but did not like the way it looked. I remade a simpler base out of walnut. The walnut base if 3/4 inches thick and 4.5 inches by 8.5 inches.

The exact dimensions do not matter, as long as the lamp is stable.

The four slots could be cut with a scroll saw or coping saw, but again I chose to use the CNC.

Wire the Socket

If you use the Color Cord Company sockets and wire they have excellent instructions on their website, so I will not include detailed instruction here. Wiring the socket and plug is straight forward. The hardest part is stripping the cloth cord. The special stripper Color Cord Company sells helps, but is not necessary.

I then attached the socket to the lamp. The socket has a threaded portion for attaching a shade, which is how it attaches to the lamp.

Cord Stay

You could use a wire fastener or cable clip, but I made one out of scrap walnut. I sketched out the shape, drilled a hole to accommodate the cord and then cut it out on the scroll saw.

To attach to the lamp I used a #8 bolt and a brass knurled nut. I counter sunk the bolt for a clean look.