Electrified McLaren Lighting

I had the opportunity to design and execute several components for Orbis Electric's McLaren MP4-12C, which is a completely stripped carbon chassis used as a test bed and demonstration platform for their latest developments in hub-motor technology.

One of these requirements for getting it back out on the streets was a complete lighting system with braking and turn signals. This included a short timeline of largely independent work with a couple interesting requirements. Functionality was paramount, but I also wanted to use as many components that were already in-house as I could. Aesthetically, it was also important to me to maintain the 'skeletal' theme of the car. On a sleek chassis of carbon and brushed aluminum, a minimalist approach was key.

Before starting, I mocked up several of our existing lights to the car with some wooden jigs to get a feel for proportions and placement. Then came sketches, CAD designs, some photorealistic renders before any orders were placed.

Before starting the build process, it was important that I could be as thorough with visualizing the design as possible to convey it to my peers and receive feedback. Here are some CAD slides, as well as some renders I put together in photoshop.

Once everything was approved, I ordered the sheet metal and got started with assembly and installation.

For secondary lights like the rear running lights, I wanted to take advantage of the unique features of an open frame vehicle. Instead of just adding lenses to the panel, I tucked bulbs deep inside the frame, covered by an open grate. This created a striking radiant effect without any visible light source.

For the center brake light, there was a recess in the frame that seemed perfect. To camouflage the bulb I visited a local glass store, and got a sample of an acrylic composite that appears matte black, but allows colored light to transmit through. I took this sample and milled it in a Bridgeport to cleanly slot into the existing frame rail.

Once everything had been installed and thoroughly tested, the final step was to take everything back apart to hit those new light panels with some scotchbrite to fix scratches and dial in that brushed finish before reinstalling.