Wilo
LED-illuminated planter to showcase and nurture your plants
This project explores the design and fabrication of a small product using thermoforming processes. The goal is to utilize the properties of thermoplastics, specifically acrylic and styrene, and demonstrate how jigs and fixtures can be utilized to ensure consistent, high-quality parts.
Year
Fall 2024
Timeline
4 weeks
Manufacturing
Thermoforming,
Mold fabrication.
Woodworking,
Acrylic cutting & bending
Initial Ideations
During the initial ideation phase, we brainstormed and sketch out their ideas for this project. The only rule was that we needed at least two plastic-formed parts, and everything had to fit within a 30cm × 30cm × 30cm space. Below, you’ll see all five sketches our team came up with, followed by the one we ultimately chose to move forward with.
Orthographic Drawings
Here are our key orthographic drawings highlighting the three main parts: the Main Housing, the Glass Cover, and the Planter. Each part is labeled in the sketch to the right, and their corresponding views with dimensions can be found at the bottom.
Manufacturing Phase I
Wood Main Housing Construction
During the construction phase, our team carefully refined each component of the plant lamp to ensure precision and functionality. We started with the base, cutting a 2cm-thick maple wood piece to size before gluing and clamping it for stability. Once dried, we sanded the surface smooth and applied a protective finish to enhance durability and aesthetics..
To integrate additional functionality, we designed and 3D-printed a custom track system that allows the case to slide smoothly into place, ensuring easy access to the plant. We also printed a water-catching tray to prevent excess moisture from leaking onto the base.
Finally, I prepared the top section for the light fixture by carefully marking the placement and using an electric drill to create an initial opening. I then refined the hole with a chisel to ensure a snug and precise fit for the light. Once it was positioned correctly, I secured the fixture with industrial-strength adhesive, completing the structural assembly of the plant lamp.
Manufacturing Phase II
Thermoforming/Plastic Parts
For the planter jig, we stacked and glued three wooden blocks together, then shaped them meticulously using coarse and fine sandpaper until we achieved the desired contours. This jig was essential for forming a consistent planter shape.
To create the planter, we vacuum-formed a heated 1/8-inch white styrene sheet over a mold, ensuring it captured all details. Once cooled, we refined the shape using a Dremel with sanding and cutting attachments, smoothing edges and trimming excess material. We also drilled precise holes for drainage and structural needs.
For the acrylic cover, which helps retain moisture, we heated a 1/8-inch clear acrylic sheet with a strip heater until pliable, then carefully bent it to the desired shape. After cooling, we sanded the edges with a belt sander for a precise fit, ensuring a clean, polished finish.
