Outside of my project management job, I freelance metalwork/CAD designs, often from concept to fabrication. Most of my designs are tailored to the clients preferences including but not limited to material already procured by the client, space constraints, or client needs.
I made a few of these in different styles prior to photographing/documenting the process. Some were made in odd shapes, like asymmetrical bent round tubing with a cutout to have recessed LED strips integrated into the structure itself. For this lamp pictured on the left, I originally intended to have a cutout at the bottom of the plates themselves with a clearance fit to have the LED strip integrated seamlessly into the lamp, however due to a lack of a laser cutter, I changed the design to have the lamp sit on square tubing with a cutout above to mimic the same effect of the original design, without the need for a laser cut-out, and with an interference fit to prevent the LED strip from slipping. Without sophisticated tools, I often need to get a little creative with the setup of my pieces. For the layers of the lamp, I cut them out using a grinder to get them all roughly within +/- 5mm. After rough cuts, I clamp them together and use a flap wheel to get the surfaces level to each other, I deburr all edges and begin assembly. In this lamp, I decided to purposefully rough up one side of the plates with a wire wheel to hide the imperfections created while fabricating, the other side (the side covered with vinyl) I approach in a similar manner by sanding the edges with small imperfections, resulting in a unique look of polished/sanded steel. I 3D print some washers in TP90 to prevent the loud metal-on metal-sound when moving/vibrating, and to provide some nice asymmetry and contrast to the all stainless look. Since I could not decide between a vertical or horizontal lamp during prototyping, I just made sure to make the lamp balanced both vertically and horizontally to be able to use it as desired, the result is a nice ambiance light that can also prop open your door on a windy day (pretty heavy.)
For the sidewalls of the planters, I designed the walls to be at a 25° offset from the perpendicular, to be able to be narrow, while allowing ample space for plant roots to grow while remaining narrow. I cut the triangles off the sheet metal using cutoff wheels, measured my square tubing to join at a point, while maintaining the same angle of the triangle walls. I tacked the square tubing together, ensuring the material was at the angle I needed before doing full welds. I did the same for the triangle walls, ensuring that the weld covered about 1/4 of the full length to prevent any water from seeping out while maintaining the sharp edges of the design. To hang the planters, and give the illusion of it levitating. I picked some safety wire (thin while still being strong enough to carry 100lbs on one line, which is well above what the planters weight with plants, soil, and water) drilled through the edge of the square tubing, and using a ferrule and stop sets (and rubber stopper to prevent corrosion from aluminum contact) I created a square hanging hook that hides the top side ferrule-stop sets to keep the planters hung while giving the desired illusion.
I designed a shed for a client to be able to use his existing cement floor in his backyard. In order to avoid Austin permitting requirements, the shed was designed in accordance but the maximum allowable specifications, and with the client's intent of using it to store, and work on, his 1973 Chevelle (and tool/holiday storage.) I designed the shed to be able to open fully on both ends, allowing for airflow during workdays, a chainfall gutter system to collect water on the backside of the cement floor to keep the water collection system as far out from view as possible. For this design, I provided a BOM, and fabricated some of the gutter system, but as of 7/4, the client contacted me requesting to proceed with the entire shed construction. I am currently getting the I-beams, C-channel, and the corrugated roof/wall panels cut to size, the installation will begin by anchoring the I-beams, welding the c-channels and supports to the I-beams, and then completing the shed with roof and wall panels, followed by the gates and locking system. (Progress and images will be updated as project progresses.)
As of 8/5 I am awaiting for the client to order new corrugated roof panels and new wall siding, since the old material had rust or was rotting, but the shell has been created - posts, I-beams, and C-channels installed.