Sometimes it is hard to find the exact lighting solution you are looking for and settling for an existing product often means having to compromise on what you really need. For this reason we are often asked to produce bespoke fixtures, one-offs or adapt an existing product so that it truly meets the client’s requirements.
We have recently completed a bespoke project for the customisation of an existing Savage exterior light which needed to meet some very specific specifications for the Dutch company Madera Ribs who produce high-speed boats for the professional and military markets. Their vessels are ‘virtually indestructible’ and are designed for heavy-duty jobs including amongst other transporting personnel & cargo both around the shore line and far out at sea. Here's a look at the road to producing the product:
Enquiry
• Looking for: Deck lights to be mounted in to GRP (Glass-Reinforced Plastic) on the fore side with a direct connection to a 24v power cable and switched from the switch board
• Application: 13 metre fast power boat (RIB) to be used as a tender for a luxury yacht
• Specifics: Customisation of 10-20 pieces of the Savage 40mm Eyelid fitting with an LED colour of 3000 K (or most commonly used closet measurement) plus drivers if required. The stainless steel bezel to be finished in black finish (RAL 9005) with matchbox textured feel
The Design Phase
In order to make the 40mm Eyelid design suitable for this application we needed to make some design amendments:
• Challenge 1: We needed to consider the available space which was limited given the size and type of vessel
◦ Solution: We adapted the fitting to incorporate an inbuilt LED driver eliminating the need for space allocation for external drivers and providing the perfect solution for a 24v supply
• Challenge 2: We needed to address the IP rating to ensure there would adequate protection against the elements given the use and design of the boat
◦ Solution: The IP rating was increased to an IP67 rated version with the addition of extra gaskets.
• Challenge 3: The colour finish
◦ Solution: The special colour match and matchbox textured feel to the bezel was also discussed with our specialist finishing departments to meet exact customer requirements.
Further Recommendations
We offered a push fit sleeve option to allow easy installation and access to the light throughout the build.
Execution
Following the design process which was carried in close consultation with the client, complete Solid Works drawings were submitted to the client for approval providing a full visual render of the amended design including dimensions.
To create the unique and very customised finish, our finishing department used certain techniques to enhance the finish. The bezel had to be specially prepared in stages by layering the custom textured paint sourced specifically or the client. Images were then sent for approval. Although we usually send a sample of the finish, the client was happy to proceed from the images.
Results
The client opted to proceed with the push fit option for a few option for ease of installation and improved access to the fitting for cleaning and future maintenance. The finished product met the client’s expectations not only in functionality and style but also in finish. The unique finish to the light provided a textured, almost ‘rough’ finish - the exact look the customer wanted to achieve resulting in impressive feedback from both the client and the vessel owner’s team. As a result we are now working Madera Ribs on more projects.
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