Reception Desk W/ Dimmable LED Backlit Thermoformed Front Panels : 5 Steps

Custom Reception Desk constructed using various materials and fabrication processes. 2 desks were made for this project. One- a mirrored version of the first, otherwise identical. Desk features:

Corian Glacier White Solid Surface Tops, Thermoformed LED (Dimmable) Backlit Avonite Sirocco Front Panels and Lumicor Acrylic Resin Transaction Top

Supplies

For the Lighting:

LED light strips, wiring, connectors, heat shrink & basic tools (wire cutters, strippers,..)

power supply & dimmer, mounting clips & zip-ties & heat gun

For Constructing Casework Frame & Subtop::

metals studs, plywood, brackets, varioud screws

WilsonArt laminate & contact cement

kerf-board & MDO

heavy-duty metal brackets to support subtop and corian tops

For the Finished Assembly:

Corian Glacier White solid surface

Avonite Sirocco

Lumicor acrylic resin

1-inch standoff caps @ additional standoff hardware

SOME* Tools & Equipment:

basic Power Tools, Bits & Such

commercial convection or Infrared oven

3-axis CNC

Level, Clampd

* + more

Step 1: Build the Frame

Glue up several layers of plywood

height of the plywood parts should be thick enough to allow brackets and subtop to be screwed down.

Use 16 gauge metal studs for vertical support.

Self-tapping screws should be used to attach brackets to metal studs which are then attached to the plywood at the top & bottom of structure.

Check for level & plumb periodically

Step 2: Surface Which LEDs Will Be Applied

Cut kerf board and laminate to correct dimensions.

Test fit to structure then use contact cement to adhere laminate to kerf

Countersink screws into face of exterior kerf-board to ensure a smooth surface for the laminate to be applied.

(Interior panels are removable and require a different procedure. We will just focus on the exterior for now.)

Use a template to mark the spacing between the rows of LEDS

Drill holes at the end of the laminated panels near where the wire connections will be made. Feed wires through the holes and run to the dimmer and power supply. (See Following Steps)

Step 3: Build Molds, Machine Letters Into Avonite and Thermoform

Build molds using 2x4's and kerf board

The word "INFORMATION" was cut into the back of the Avonite using a 3-axis CNC router.

Heat avonite as directed by the manufacturer. Place on mold and leave to cool.

Cut to final dimensions.

Drill holes for attaching standoffs

Step 4: Run Lighting Across Structure and Light!

Measure the length of
mounting surface that receives the LED lighting strips, making sure to take account for any fasteners, brackets or obstructions. Layout LED strips confirming start point is at a diode & overall length also terminates at a diode. You may need to reduce overall length to accommodate & repeat for all other required strips

Prior to attaching LED strips to structure, individually hook up every LED strip to the power source & confirm usability. (Entire strip is lighting fully & appears consistent in color temperature)

Wipe off mounting surface with a micro fiber cloth to remove any residue and then carefully peel back pressure sensitive adhesive (+/- 1” to start), align LED strips to layout lines & press down firmly to adhere (whenever possible press in between the LED diodes to avoid any damage)

Leave the end of strip that will receive electrical connection free & able to be manipulated as needed to make final connection. This connection can be a soldered diode to wire type or quick connect pressure ‘clip’ type connector depending on application and type of LED strip. All connections here are ‘clip’ type connector that has +/- 18” wire whip connected.

Pre-wire all whips to fit into electrical area using zip tie clips and physical butt-connectors between separate wires.

(Obviously this was not the complete step-by-step)