Industrial Jar Wall Lamp

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Introduction: Industrial Jar Wall Lamp

About: I have a master's degree in physics and my hobbies are: 3D printing, CAD design, arduino, astronomy, astrophotography, cosmology and sci-fi :)

- Mains power cord with on/off switch

- Jar with lid (small or large)

- Copper wire (any diameter)

- PLA (alternatively ABS)

- Bulb holder/socket (E14/B15 for small version and E27/B22 for large version)

- Bulb (E14/B15 socket or E27/B22 socket)

- Glue (Gorilla super glue)

- Solder

- 2 x M3 screws

Tools:

- Screwdriver

- Soldering iron

- Wire cutters/strippers

- 3D printer

NOTE: In case of power cord, you can check example listing on Amazon, but you will have to find appropriate power cord for your country (US, UK, Europe, Asia). Similar for the bulb holder, you have to decide which size you wish to print and then which mount you wish to use (Edison or Bayonet).

Supplies

Few weeks ago I have decided to make a wall lamp for my shed. As I love 3D printing, I have decided to design the body for the lamp and use old jar as a lamp shade. The design was ready after few hours and the next step was to decide in which material to print it. I have recently bought Marble PLA for testing and I absolutely love it, so I have decided to use that material for my wall lamp project.

In this Instructable I will show you how to make industrial style wall lamp for your shed or garage, and I hope you will enjoy this project :)

Step 1: CAD Design

I have started my design in Fusion 360, which I have been using for few years now. It took about 5-6 hours to complete the original design. After test print, I had to make few small adjustments and final version was ready for 3D printing in Marble PLA.

There are two available versions, one for small jar lid and one for large jar lid - these are the most common sizes. If you wish to make a lamp for completely different jar size, you can use slicing software like Cura or Sli3er to scale the model accordingly.

Both versions (small and large) are spited into two pieces for easier printing and assembly, and should fit into standard FDM printer bed (200mm x 200mm).

Step 2: Assembly Part 1

You will your 3D printed part (main_body_1), jar lid and bulb holder in this step.

- Use scissors and cut the hole in the middle of the jar lid big enough for the bulb holder.

- Mount the bulb holder as seen on the picture above, and secure with the screw cap which should come with the holder.

- Optionally, you can paint the lid and the bulb holder to give it more uniform look

Step 3: Assembly Part 2

In this step you will need power cord with on/off switch and 3D printed part (man_body_2)

WARNING: Make sure you do this step with power cord DISCONNECTED from the mains!

- Cut the end of the cord, so you can attach the wires to the bulb holder (don't touch the end with the pug).

- Feed the power cord through the 3D printed part as seen on the picture above

- Strip wires at the ends, so they are ready to be connected to the bulb holder

Step 4: Assembly Part 3

- Connect power cord wires to the bulb holder which you prepared in step 1

- You will have 3 wires (yellow, blue and brown). We won't use yellow and this lamp don't have ground GND, so just cut this cable and leave in insulated. Brown and Blue wires are Live and Neutral wires and those you need to connect to the bulb holder.

- Glue both 3D printed parts together using super glue (I recommend Gorilla superglue)

- The jar lid should fit nicely into the 3D printed part but you can add few drops of glue if you like

- Insert the bulb into the holder

- Wait few hours for the glue to bond two 3D printed parts

- Now you can plug the cord into the mains and use on/off switch to test if the bulb will light up

WARNING:Please inspect the entire power cord for any damages in the insulation before plugging it into mains, and make sure that you don't have any exposed wires.

Step 5: Assembly Part 4

This step is optional, but it will give your wall lamp nice industrial touch.

- Wrap the jar with copper wire and then solder both ends together (make at least 3 loops as on first picture)

- Cut short pieces of copper wire and place them from top to bottom of the jar

- Solder all intersections between wires (it's up to you how dense the wire net you wish to make)

WARNING: Be very careful when soldering. Make sure you use lead free solder and that you have fume extractor switched on.

Step 6: Mounting on the Wall

To mount the lamp on the wall, use two screws as seen on picture above and then just slot the lamp onto them (if mounting on wall use wall anchors). Then plug the power cord to the main socket and the lamp is ready :)

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    11 Comments

    0
    bryans workshop
    bryans workshop

    1 year ago

    Really nice! That copper cage is sweet!

    0
    poblocki1982
    poblocki1982

    Reply 1 year ago

    Thanks :)

    0
    bulldog85043
    bulldog85043

    1 year ago

    Where did you source the jar for your example? It a great project! I’m hoping to do the holder in wood PLA soon.

    0
    poblocki1982
    poblocki1982

    Reply 1 year ago

    My grandparents used have similar lamps in the stable years and years ago (30 years to be exact) and as I enjoy 3D modelling I'm constantly looking for new projects :) It should look pretty cool in wood PLA. If you do print it please send me a picture.

    0
    NirL
    NirL

    Question 1 year ago

    Thanks sharing :) looks great!
    Does the glass jar ever get too warm? Do you think it might fail?

    0
    poblocki1982
    poblocki1982

    Answer 1 year ago

    I've had light on for 4-5 hours, sometimes longer and no issue so far. Just to be on safe side you could use SMD light bulb which literally don't produce any heat. Another advantage of using SMD LED is energy consumption which is very low.

    0
    Penolopy Bulnick
    Penolopy Bulnick

    1 year ago

    Really nice design! I like how much the copper wire adds to it without really being a big part of it :)

    0
    poblocki1982
    poblocki1982

    Reply 1 year ago

    Thank you :) I agree, copper wire completely change the design. I'm also planning to print it in different materials like wood-fill or copper PLA. Should be interesting

    0
    AnandM54
    AnandM54

    1 year ago

    Amazing startup with CAD!!!

    0
    poblocki1982
    poblocki1982

    Reply 1 year ago

    Thank you :)