Each lamp goes through a lengthy process before it is ready for production.
Dan begins sketching a variety of designs on paper before moving to the computer. Next he models his ideas in 3D modeling software where he can easily manipulate components and dimensions to help realize his ideas. Many lamp designs don’t make it beyond this point.
Low resolution computer model in Sketchup
The first physical prototypes are often produced by Dan out of styrofoam or scrap wood. They are rough proof of concepts to help him decide if he likes the idea “made flesh” as much as he does the virtual versions.
Fully wired, painted styrofoam model
The next step is to let the master woodworkers and glassblowers work their magic.
The glassblowers typically go through several trials and errors before getting the shape and coloring just as intended.
Using timeless joinery techniques and an understanding of the properties of the different types of wood, the woodworkers figure out what modifications are needed to be able to produce these models consistently and with the sort of durability to last several lifetimes.
Tim McFadden picks out imperfections in the glass
Each lamp is produced using sustainable domestic hardwoods such as Maple, Cherry and Walnut. Almost all joinery is done with traditional joinery techniques such as mortise and tenon, dovetail or dowel. Modern machining techniques may also be used to produce several of an intricate part thereby elevating the craft and what we are able to produce. Each is finished with several coats of a quality, low VOC polyurethane such as typically used in high end custom cabinetry that enhances the wood grain while keeping the lamp protected and maintenance free.
The glass is typically colored with several layers of dye on both sides to produce rich colors and attractive gradations.
All lamps use standard medium base bulb sockets or small candelabra sockets and are designed for easy bulb replacement. Each has a rotary dimmer and comes with bulbs carefully selected for that particular lamp.
All electrical components are UL listed for peace of mind.