Contract Manufacturing
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3D Modelling
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Assembly & Commissioning
Prototyping
Architectural
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Architectural Lighting Ring

Overview
Industry
Architectural
Location
Sydney, Australia
Services
Contract Manufacturing
Engineering Consulting
Technologies
3D Modelling
CNC Machining
Assembly & Commissioning
Prototyping
A bespoke 6.3m aluminium lighting ring was engineered and manufactured as the centerpiece for a performing arts venue. Designed to appear as a single seamless structure, the project required early-stage design input, precision machining, and strategic prototyping to overcome challenges around material availability, coating processes, transport, and cost. We provided manufacturing direction during the design stage, ultimately delivering a 12-section assembly— pre-fitted and marked in-house to ensure a seamless reassembly and installation on site in Australia.
6.3

Meter diameter lighting ring

60

Individually machined components assembled to look like one piece

240

Sets of visibly concealed fasteners to fix the assembly together

Background

Our client approached us with the requirement of designing and building a lighting ring as a focal piece in a performing arts space. The lighting ring had to deliver on both functionality and compliance to the surrounding space’s aesthetic.

Challenge

The requirement was to create an assembly which looked to be created from a single piece of metal. In addition to this, material availability, design for manufacture, post machining coating limitations, freight limitations and budget were all key project constraints.

Solution

Working with our customer, we provided direction through the design phase with regards to method of manufacture. Prototypes were manufactured early on to prove theory and determine finish specs. The final product resulted in a 6.3m diameter lighting ring assembly. Comprising of 12 major sections, each made of 5 CNC machined components. Machining accuracy and final fitment was critical to give the visual perception that the lighting ring was created from a single piece of metal. It was assembled and mating components marked at Stafford Engineering before being disassembled and shipped to our customer in Australia before the 12 sections were coated and reassembled on site for installation.

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