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Blow Moulding & Vacuum Metalisation

Blow Moulding & Vacuum Metalisation

Blow Moulding & Vacuum Metalisation

Techniques Tom Dixon have developed over several years, working with German engineering and manufacturing experts.



Some of our most recognisable lights: Copper, Mirror Ball, Melt, and Cut are created through a process of blow moulding and vacuum metallisation to achieve perfect spheres, melted orbs and faceted gems with abundant and unusual luminosity. Over several years we have worked with some forerunners of German engineering and manufacturing to develop these techniques and produce lamps that create the latest in reflectivity and transparency.


Tom Dixon Mirror Ball Ceiling Light

Mirror Ball Pendant Lights


The intended aim of the original Mirror Ball and Copper was to produce a completely spherical, highly mirrored object. Through the use of Injection Blow Moulding, a melted plastic polymer moulding is injected into a massive precision made steel tool, inflated with compressed air and then cooled. We use this same technique to achieve the silhouettes for Melt and Cut.

The perfect mirror finish of each pendant is then created by the highly technical process of vacuummetallisation. The polycarbonate shell is secreted in the interior of a metallic chamber, the air sucked out, and an immense electrical charge channelled through. With a bang and pop a thin strip of copper foil is vaporised into a fine mist of metallic particles that settles across the interior. 


Tom Dixon Melt LED Ceiling Light

Melt LED Pendant Light


For Melt and Cut we have taken vacuum thin film deposition to a new level with half metallised surfaces, creating an extraordinary optical effect that reflects and enhances its environment. This half-mirrored effect often seen on a smaller scale in fashion sunglasses or gangster windscreens creates a hyper reflective surface finish when turned off but transforms into a translucent colour when switched on.


Tom Dixon Cut Ceiling Light Process


Tom Dixon Cut Ceiling Lights

Cut Pendant Lights


Tom Dixon Copper Ceiling Light

Copper Pendant Light