The Dome Light (name likely to change) is a table lamp with a radial disc that rotates around an internal dimmer switch.


It was born out of a simple form that was informed by an intuitive feeling for a glass dome resting on a simple wooden base. Early sketches will help illustrate what this idea looked like initially.

An initial rendering that came from these sketches looked like this:

From this I got the idea of adding functionality to the dial, which to that point had been decorative (it needed something more than just glass and wood; in this case aluminum).

I realized that the form suggested a radial motion and would naturally fit with the use of a dimmer switch. The next rendering was with that in mind:

I also created a diffuser for the lighting element (most likely a group of LEDs) to soften its appearance as well as making it more consistent with the shape of the glass component. I notices that handles dictate sides for the light (front and back) and that it would be better if the light had no ‘side’, keeping it consistent with its round shape. So I ditched the handle design in favor of a dial. This way the light can be placed on any surface without needing to worry about orientation (if it is next to one’s bed for example).

The following rendering shows this:

Another issue that I will need to resolve is in making or modifying a dimmer so that a full rotation is not needed in order to bring the lights to full brightness. This is so that only the dial will move.

The following exploded view will help to illustrate what I mean.

The bottom and the top of the base are to be connected to each other either with glue or screws. So allowing for the greatest amount surface area that can be made available for the top part of the base to join the lower is structurally critical. Therefore, a dimmer switch with a 1/4 turn or slightly more is possible. I will need to get in touch with someone that is good at modifying switches…

Another issue that will require prototyping to address is making sure that the base of the light and the glass dome is heavy enough to prevent the light from moving when the switch is rotated.

As far as wiring is concerned, I found a company in Sweden that makes fabric covered cords that come in a huge variety of colors. I think the cord should be address with as much sensitivity as the rest of the light. Here is a link to that company.

Disraeli Gears

Invariably there is a part in most design work where a certain detail takes up a disproportionate amount of time to resolve. So far with the Dome Light, this would be the geared dial mechanism. Having no background in engineering, the entry into gear design was a bit more involved than I thought. What did I know about Diametral Pitch and how to properly calculate it? Thanks to my buddy, the internet, I was able to find gear formulae (here). But so far, this has not resulted in perfectly crafted and meshing gears. Part of the problem is that my gear variables do not result in Diametral Pitch values that SolidWorks likes (I keep arriving at ’7′ and it wants ’6′ or ’8′). I have tried to fiddle with different dimensions to make this work, but so far no luck.
Here is a rough, semi-functional assembly that I have been working on:
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