How do you convert a line drawing into a layered design for laser cutting? We asked Rodolfo from Lekky Studio. In this article, Rodolfo takes you through his process and teaches you how to design and create a wooden lamp yourself with your laser.
In this blog, I'll show you how I turn a flat illustration into a layered 3D wall lamp. I'll take you step-by-step through the design process, preparation for the laser, and final assembly. What I find cool about this project is that with a clever design, you can create a functional lamp with depth and character.
In my studio, I use a 100W Aeon Laser CO₂ laser, but any laser cutter capable of cutting plywood is suitable for this project. I would recommend using a light type of wood, such as 4 mm thick Linden plywood.
The Idea: A Tattoo as Inspiration
Collected inspiration images of swallow patterns
Every design starts with an idea. I enjoy looking at tattoo culture, and for this lamp, I drew inspiration from the recognizable swallow. Everyone recognizes this symbol; sailors used to wear it as a badge-of-honor. One swallow meant the wearer had sailed 500 nautical miles, two stood for 1000 nautical miles.
I am not a sailor myself, but this seafaring culture appeals to me because I have spent a large part of my life around the Caribbean Sea. I now live in Hengelo, and this swallow reminds me of the long journey and experiences that have brought me to where I am today.
Besides this personal meaning, the shape of the swallow is strong and recognizable. It's a line drawing, but I'm going to show you how to transform it into a layered design.
From the start, the goal was not to create a flat decoration, but an object that already has sufficient depth even without lighting. By combining multiple layers, a design emerges that changes as soon as the lamp is switched on.
Step 1: Sketching on Paper
First technical sketches for the lamp holder on paper
Before I sit down at the computer, I first work out my ideas on paper. In this photo, you can see the first technical sketches of the lamp holder on the back.
Developing this construction took quite some time initially. I made several prototypes out of cardboard to check if all parts fit together properly.
You also need to consider the material thickness, in this case 5 mm poplar plywood, and sufficient space for the lamp holder and assembly. I have been using this material for years and have come to appreciate it more and more. It is lightweight, which is important for a wall lamp that consists of multiple layers and will eventually hang on the wall.
Additionally, poplar plywood has a natural wood structure that remains visible in the final result. Its light beige color works excellently as a base for paint, but also looks beautiful when you leave parts untreated or finish them with wood stain. It is a versatile material that is also very easy to cut with a laser.
By testing first, you prevent unnecessary errors during laser cutting.
Step 2: Digital Refinement in Adobe Illustrator
Tracing the drawing in Adobe Illustrator
Once the sketch is final, I take a photo of it with my phone and refine it digitally in Adobe Illustrator.
Using the Pen Tool, I redraw all lines as vectors. This requires some practice at first, but it gives complete control over the shape and makes the design suitable for production.
Creating the back layer in Adobe Illustrator
For the back layer, I make a copy of the swallow and give it a thicker contour. Then, I convert this contour into a single closed vector shape via Object > Expand and combine the parts with Pathfinder > Unite. After removing the inner remnants, a solid backplate is created.
Personally, I export the design as PDF before importing it into the laser software. SVG also works fine, but I personally find PDF to be slightly more consistent during import.
Step 3: Preparing in LightBurn
Assigning different colors to the laser file in LightBurn
Once the design is ready, I import the file into LightBurn and link different settings to different colors.
For this project, I'm using a 100W CO₂ laser and 5 mm poplar plywood.
The settings are as follows:
- Pink lines (cutting): speed 20, power 60.
- Green lines (marking): speed 400, power 10.
The green lines are used as positioning marks on the back of the swallow. This way, during gluing, I know exactly where the lamp holder needs to be placed.
On the cut parts, you'll also see a small rectangular hole. This has two functions: it helps with precise positioning of the back construction and simultaneously forms a mortise and tenon joint that adds extra strength to the whole assembly.
Before the machine starts, I always double-check the focus, the material's position, and the selected starting point.
The backplate of the swallow lamp is being cut by the laser cutter
The cut backplate, with engravings and the rectangular hole, ensures everything can be positioned very precisely.
Step 4: Finishing with Color
These colors I used for the lamp
After cutting, the various parts are finished with spray paint. For this project, I use spray cans from Montana Colors.
I enjoy working with them because they provide excellent coverage, especially on porous surfaces like wood. Additionally, they dry quickly, allowing you to work efficiently without long waiting times between layers. I also have good experiences with the paint's durability.
What I personally find most pleasant is the enormous choice of colors. The range seems almost endless, so I can almost always find exactly the right color for a design.
For this lamp, I chose a combination of matte black, a deep blue-green color, and bright red. Some parts are deliberately left untreated so that the natural wood structure remains visible.
The combination of paint, wood grain, and the dark laser edges creates an interesting contrast and adds extra depth to the design.
Step 5: Building the Construction
Assembling the holder
The holder at the back consists of multiple loose parts that together form a sturdy construction for the lamp holder and the lamp.
For assembly, I use cyanoacrylate adhesive. Over the years, this has become my favorite adhesive for these types of projects due to its very strong bond and fast drying time.
Previously, I mainly used wood glue, which is still an excellent choice, but I found myself spending a lot of time waiting for everything to fully dry. With cyanoacrylate, I can continue working almost immediately. That makes the process more efficient and helps to complete projects faster.
However, this adhesive requires caution. Some variants are very liquid and can easily get into places where you don't want them.
I have learned that myself over the years. I have damaged tables, chairs, and floors more than once by not using enough protection. That's why I now always work on cardboard or another disposable material that can get dirty or damaged. Just as with painting, careful work here prevents many problems afterward.
One tenon protrudes so that the holder can be perfectly aligned during assembly
During assembly, you'll see that one of the wooden cross connections protrudes slightly. This tenon slides precisely into the rectangular hole of the swallow and ensures that the construction automatically aligns to the correct position.
Afterward, the colored layers on the front are glued one by one until the complete design is built up.
Result
The lamp inspired by the swallow tattoo is finished
When the lamp is fully assembled, the back construction forms a sturdy base for the E14 lamp holder, and the entire piece is ready to be mounted on the wall.
Due to the multi-layered construction, a clear depth effect is created both during the day and in the evening. As soon as the lighting is switched on, the shadows and different levels reinforce each other, giving the design an extra dimension.
Hopefully, this process provides a good insight into how you can transform a simple illustration into a functional and layered end product.
Are you curious about more projects or want to follow my method? Feel free to take a look at my Instagram: @Lekkystudio.
You might also find this interesting: How do you design a personalized crate for laser cutting?
In this tutorial, you'll find a drawing generator that creates box shapes with suitable finger joints for you, which can also be used as a basis for, for example, a lamp holder.
