Inside the custom-formed housing, we installed three rows of amber LED strip, bonded using our specialized adhesive systems. The entire assembly was then filled with a specially formulated LED resin, which provided:
- Complete waterproofing and environmental sealing
- A homogeneous, continuous light diffusion
- Structural reinforcement and vibration resistance
To complete the design, we 3D-printed custom end caps from high-strength nylon, ensuring precise fitment and long-term durability.
Where It Was Used
The Olli shuttle featured:
Integrated Expertise
This project was an excellent combination of our adhesive knowledge, metal forming capabilities, LED lighting experience, and LED resin casting expertise — all working together to deliver a robust and visually cohesive lighting solution.
Two long curved light fixtures on the front
A Valuable Experience
Although Local Motors closed its doors in 2022, the Olli project remains an important milestone for our team. It gave us valuable experience in developing custom lighting fixtures for EV and mobility applications and strengthened our foundation in automotive-grade prototyping.
At 865FabLab, we continue to apply these integrated fabrication skills to new projects in lighting, design, and advanced product development.
Learn More:
https://www.perronerobotics.com/tony-olli
https://www.robotics247.com/article/local_motors_developer_of_olli_autonomous_shuttle_shuts_down
Key Materials & Techniques Used
(Sidebar module – HubSpot Clean Theme)
- Aluminum LED Channel:SLW10 surface-mount profile
- LED Type: 12V amber LED strip (triple-row configuration)
- Adhesives: High-performance bonding system for aluminum and plastic interfaces
- Encapsulation: Custom-formulated LED resin for optical clarity and waterproofing
- End Caps: 3D-printed nylon components (high-strength polymer)
- Forming Method: CNC-guided roller bending for curved light profiles
- Finish: Continuous, diffused amber illumination
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