Project Overview
A luxury villa in Elk Grove, California, sought high-end, functional lighting for a private football field. The client required:
– A sculptural 3D aluminum lamp arm with flawless welds
– Integrated frosted acrylic diffusers for soft, glare-free illumination
– Stainless steel net mounts to contain footballs within the property
Engineering & Design Highlights
1. Precision 3D Lamp Arm Fabrication
– Construction:
– Aluminum plates + tubular frame welded into a hollow 3D structure
– Intubation welding for seamless internal reinforcement
– Challenges:
– Avoiding warping from excessive heat during welding
– Maintaining visual cleanliness (no visible weld marks)
– Solutions:
– Master TIG welders used low-heat intermittent welding
– Post-weld CNC polishing for a smooth, brushed finish
2. Custom Acrylic Light Diffusion System
– Design:
– Laser-cut frosted acrylic panels fitted into the arm’s hollow structure
– 30W LED module mounted beneath for uniform, low-glare lighting
– Key Detail:
– Acrylic was inserted before final assembly to ensure perfect alignment
3. Football Net Retention System
– Stainless steel buckles (4x per pole) for attaching a high-tension net
– Designed to withstand impact from footballs without damaging the pole
4. Pole Body Construction
– Hydroformed aluminum for smooth, consistent bends
– Stretch-bending process to achieve the exact curvature
Result: A Perfect Blend of Form & Function
Sleek, high-end lighting that complements the villa’s aesthetics
Glare-free illumination perfect for evening games
Durable net retention to keep footballs within bounds
Why This Project Stands Out
Bespoke 3D aluminum fabrication – merging art with engineering
Multi-functional design (lighting + sports utility)
Luxury residential-ready finishes
