CeramicsConsumer ProductsDesignFurniture

Lamp designed by Paolo Castelli showcases 3D printing in mid air

Haibu lamps were 3D printed using WASP's LDM technology

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There were many 3D printed lighting products on display this past April at the Salone del Mobile expo in Milan, including Rollo Studio’s Sun Lamp Collection and customizable 3D printed lamps developed by Philips. For the first time, historic furniture design company Paolo Castelli Spa (which was roots dating back to the 19th century), also presented a 3D printed suspension lamp. This new outdoor lamp series, called “Haibu”, was created using computational design and mid-air ceramic 3D printing in partnership with WASP.

Paolo Castelli 3D printed lamp WASP
(Photo: WASP)

The lamp design itself draws from the organic structure of a hive as well as an interwoven pattern that results in a calm, dynamic lighting. To bring this concept to life, Paolo Castelli designers enlisted the help of WASP, an Italian 3D printing company specializing in large-scale and ceramic extrusion technologies. Vittorio Paradiso, designer at Paolo Castelli, says: “For the new collection, we felt the need to create a product that was cutting edge. Because of this, we started looking for a company that could assist us in the technical realization of the product. Therefore we chose WASP, a company from our area, as technical partner for the project.”

In the creation of the lamp, WASP first used computational design to create a parametric 3D model based on Paolo Castelli’s design. From there, the 3D model was optimized for WASP’s large-scale Liquid Deposition Modeling (LDM) technology and subsequently printed using the company’s WASP 40100 LDM and WASP 3MT LDM machines. One particularly unique aspect of the outdoor lighting fixture’s creation was that it used mid-air 3D printing to achieve both a dropping curved shape and to create thin slits between the ceramic layers through which light can pass through. This method, of printing in thin air for portions of the lamp, demonstrates how rules can be broken (so to speak) to achieve unique creative results.

Paolo Castelli 3D printed lamp WASP
(Photo: WASP)

As Paolo Castelli explains on its website: “As the material is printed and dried, it spontaneously falls back on itself, thus creating a pattern of slits that allow gentle beams of light to escape. The refined design then blends with the intrinsic properties of the material in a durable lighting system that invites to experience moments of relaxation in the open air.”

Paolo Castelli 3D printed lamp WASP
(Photo: Paolo Castelli Spa)

The Haibu suspension lamp series is part of Paolo Castelli’s Acquerello Collection and comes in two variations: an elongated lamp fixture or a wider structure. In addition to using 3D printing for the lamp’s distinctive hive-inspired design, Paolo Castelli was also drawn to the technology to meet its sustainability goals. That is, the furniture design firm wanted to create a product that was sustainable in terms of its materials and production method. Crafting the outdoor lamp from natural ceramic materials and using a process that minimizes material waste was therefore in line with the brief.

In addition to supporting the Haibu lighting series, WASP also worked on other projects on display at Salone del Mobile 2024. For example, the company worked with Netherlands-based IOUS Studio on a collection of parametrically designed Cloud lamps, and helped bring the Milan “Dropcity in-progress” project to life.

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Tess Boissonneault

Tess Boissonneault is a Montreal-based content writer and editor with five years of experience covering the additive manufacturing world. She has a particular interest in amplifying the voices of women working within the industry and is an avid follower of the ever-evolving AM sector. Tess holds a master's degree in Media Studies from the University of Amsterdam.

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