Custom LED brake disc lamp with personalised centre cap

Project snapshot

The brief

The client wanted a decorative brake disc lamp that looked dramatic when switched on, with a warm orange glow suggesting an overheated performance rotor. The piece also needed a personal touch, so the centre cap area was customised with text for the recipient.

This was not a simple single-part novelty print. The project needed proper part separation, reliable assembly, real fasteners, integrated lighting and a finish that would look good as a display item in a home, garage or workshop.

What mattered

• A strong visual “glowing brake disc” effect
• Clean multi-part assembly instead of a simplified one-piece shell
• Secure fixings for repeated handling
• A personalised centre detail that felt integrated into the design

Design and manufacturing approach

1) Multi-part FDM build for a cleaner end result

The lamp was manufactured as a set of separate FDM-printed parts rather than a single combined print. That made it easier to clean each piece properly, keep colour zones crisp and assemble the lamp with better control over alignment and finish.

The main structural parts were printed on Bambu Lab P1S and P2S machines in PLA. Multi-colour elements were produced using the Bambu Lab AMS system, which made it possible to keep text and contrasting parts flush and neatly separated without painting.

2) Post-processing and mechanical assembly

Once printed, the parts were cleaned individually. Support material was removed where needed, visible edges were checked and small imperfections were refined. Minor stringing was cleaned with controlled heat finishing.

To improve the durability of the build, brass heat-set inserts were installed in the required locations so bolts could be threaded into the plastic securely. The fasteners were also supplied and fitted as part of the finished assembly.

3) Integrated USB LED lighting

The lighting system used a 5V LED strip with a USB cable and inline switch, supplied and installed as part of the complete project. The strip was positioned behind the orange diffuser ring so the disc glowed evenly once powered.

Some sections were additionally secured with cyanoacrylate adhesive where permanent positioning was needed, particularly around the diffuser and other non-load-bearing joining points.

4) Final assembly and visual result

Once assembled, the lamp combined the disc body, black caliper, personalised centre cap and illuminated diffuser into a single display piece. The final lighting effect is what gives the project its character: it looks much more like a finished custom décor item than a simple printed model.

Result

The finished piece measured approximately 25 × 30 × 10 cm and was delivered as a complete personalised lamp for £75, including design preparation, printing, finishing, hardware, lighting integration and assembly.

This case is a good example of how FDM printing can support more than just functional prototypes. It also works well for custom presentation pieces, enthusiast décor, personalised gifts and mixed-media assemblies where printed parts, electronics and finishing all need to come together cleanly.

Related: FDM 3D Printing, PLA, 3D Design & File Support, Get a Quote.