From Concept to Completion: The Custom Lighting Process
From Concept to Completion: The Custom Lighting Process
The custom lighting process begins with a conversation. An architect, designer, or homeowner brings a need -- a new commission, a historical restoration, or a space that calls for something unique. What happens next is where Crenshaw differs from most lighting companies.
Design and Engineering
Every custom piece starts with design work done in-house. Using SolidWorks, Rhino, and ZBrush, the design team develops initial concepts. Unlike companies that buy finished components from overseas and assemble them, we design from raw material. This means the design isn't constrained by what's available from suppliers -- it's constrained only by physics and budget.
The engineering team works alongside designers to ensure every piece can be fabricated. This matters for custom work: a design that looks good on paper doesn't always translate to brass, steel, or glass. In-house engineering catches problems before they become costly mistakes.
Fabrication
Once approved, the design moves to the machine shop in Floyd, Virginia. The 50,000 square foot facility houses CNC mills, manual mills, lathes, waterjet cutting, and SLA 3D printing. For brass and steel work, the machine shop produces components to exact specifications. For glass work, the hot and cold glass studio handles blowing and cutting.
Most competitors don't have these capabilities. They purchase finished components and assemble them. This works fine for standard products. It doesn't work for custom work that requires specific materials, finishes, or historical accuracy.
Testing and Certification
Custom pieces aren't exempt from testing. The UL co-witness laboratory on-site can test custom designs directly. This matters for institutional projects -- government buildings, colleges, hospitals -- that require specific safety certifications. Over 100 LED listings through UL testing means we understand what certifications require and can design custom pieces that meet those requirements from the start.
Finishing
Finishing happens in-house, too. The paint studio handles powder coating and liquid finishes using PPG automotive grade products. The patina studio applies hand-applied finishes to brass and other metals. This level of control over finishing allows for specific historical accuracy -- matching original finishes from landmark buildings requires materials and methods that can't be achieved through outsourced finishing.
What This Means for Your Project
The entire process -- design, engineering, fabrication, testing, and finishing -- happens under one roof. This means:
- Faster turnaround on design changes
- Quality control at every stage
- Historical accuracy for restoration projects
- Specific material and finish requirements that can't be met by importers
It also means we're not limited by what competitors can buy from overseas. If a project requires specific brass alloys, custom glass, or historical patinas, we can make it.
Recent Custom Projects
The 15 Central Park West commission required custom geometric chandeliers with specific glass and finish requirements. The Laurens County Courthouse restoration needed historical accuracy down to the patina finish. These projects didn't require us to ask a supplier if they could make something -- we designed and fabricated them in-house.
The process doesn't change whether the project is a single fixture or a hundred. The same capabilities that produce custom work for the US Supreme Court are available for a private residence.
Ready to discuss your custom lighting project? Contact us to start the conversation.
