This an easy to make lamp-shade if you have acces to a 3d-printer and a lasercutter. All you have to do is make the pieces and put it all together. But some knowledge of vector design software could be used to customise your lamp.
-Plywood 850 x 350 x 5mm (I used 5mm, but you can use every thickness, just keep in mind that you have to change the length of your bolts as well)
- 180 M3x8mm bolts
- 3d printer
- Sand paper
- Bulb fitting
- bulb +/- 60 watt
Step 1: First: Print All Your Pieces
Start with printing 60 (!) of the vertices connectors. Mind the little pentagon-shaped hole, this will be important. I printed this on an ultimaker original with a .4 nozzle. Layerheight .15. No support or brim.
If you don't want the inner faces you only have to print 4 of the little spacer hooks. This is because of the fitting which has to be attached in the inner face with the hole in the middle. For every inner face you want to use you have print at least 2 spacer hooks.
Step 2: Start Customizing Your Lamp
If you don't know how to use vector editing software or don't want to, you can skip this step.
Use vector editing software to customise the inner faces. I used Adobe illustrator, but there are a few free vector editing programs out there ie.: inkscape
Feel free to experiment, in my experience you won't use all of the inner faces because that will be a bit dark, so you can go extreme just to see if it works. If it doesn't, there are still a lot of inner faces left. But keep in mind that the inner faces must have some kind of frame on the outside to hold the spacer hooks!
Step 3: Lasercut All Wooden Pieces
Just as the title says: Lasercut. That's all. Settings depend on your lasercutter and the plywood you bought. The only thing you have to do when everyting is cut, is sand all pieces to get rid of the residue.
Step 4: Putting It All Together
Before you start screwing it all together, take a look at your corner pieces. If all went well, you should see a little dimple near one of the screw holes. This is the side where the pentagons go. So every corner piece has 2 hexagons and 1 pentagon to connect to.
Start with a hexagon and screw on 6 corner pieces you printed. Add hexagons and pantagons accordingly (3 hexagons and 3 pantagons). Make 2 of these shells. Put one aside for the end.
Take the other shell and just keep on screwing on pieces, this will take some time. When every piece is used you will only have to attach the shell you put aside and your frame is done.
Now you'll have to put in the faces using the spacer hooks. Start with the one inner face with a hole inside so you'll know what the top will be. Insert the bulb fitting through the hole and attach it at the top.
If everything is to your liking, mount it to the ceiling and turn on the light! Your Lasercut and 3d-printed Truncated Icosahedron lamp-shade is done!