Assessment 3: Tutorial- The Blister
The Blister!
Materials
- Aluminum sheets 10mm
- MDF sheets 12mm.
- Sand paper
- Bolts and washers.
- Permanent Marker.
Tools
- CNC machine
- Guillotine to cut the material evenly
- Hand file
- Tinsnips
- Scribe
- Spanner
- Flat and tapered nylon hammer
- Mallet
- Planishing hammer.
Safety
1. Eye, ear and foot protection is necessary
2. Safety induction
Method:
Step 1: To make the blister, split up into groups and establish communication with your groups. This will allow you to distribute material between you all.
Step 2: Use a scribe and ruler once again to measure a piece of metal that fits on top of the stencil we The metal should be about 50mm more on every side to allow for shrinking and expansion.
Then cut this piece on the guillotine.
Step 3: You and your partner must select the template of a teardrop that you want to use. There will be a selection of over 30 teardrop shapes. These templates will be created and cut using the CNC laser cutter in the backroom of the workshop.
Step 4: You and your partner take turns to do your own job so take it upon yourselves to help each other when necessary. The CNC cutter left little tabs on the cut so that it would not fly off while cutting, therefore with a bandsaw, cut the little tabs were cut to create a perfect template of a teardrop on both pieces created, as you will receive two copies of the template.
Step 5: The metal sheet cut was placed between the two templates and screwed together together as accurately as possible to ensure the metal sheet within did not move or shift whilst being worked on. This is important as it can cause complications and errors in the overall design of the tear drop that can delay the process and ultimately create a defect in the end product.
Step 6: Using the white mallet, the metal piece within should be tapped gently using the sharp end to push the sheet down in to the space created. The goal is to create a downward curve to mimic the shape of a three dimensional teardrop. This process should be repeated until you can not hammer anymore due to the fact that you will reach the workbench below which would make the tear drop begin to form a flat surface.
Note: it is extremely important that heavy hitting is not used as any little mistake can alter the finish product, therefore you should also use a variety of other hammers and objects that fit the template, that allow for smooth work and minimal damage to the metal sheet. This will be in the form of a curved piece of timber being hit by the mallet as well as placing a smaller wooden mallet in the template and hitting it with the larger mallet softly and consistently in a downward motion.
Step 7: Then you will use small timber pieces, drill them into the bottom of the template to hoist up the overall job, thus allowing you to continue working on the teardrop with out it hitting a flat surface. You should aim to get the peak of the teardrop to go beyond the template by 5mm and end up getting it to about 15mm as shown.
Step 8: Equally measure from the centre to the edge on each side and slightly trim the edges so that the blister looks neat and tidy as well as accurate. This will allow you to begin the final stage of the project, finishing.
Step 9: The flat head hammer will be used slightly in this project to soften and straighten out any little bumps created but there should not be many as no sharp or metal objects should be used directly on the blister.
Step 10: Finally the job should be sanded both in the workshop and if necessary also at home to create a smooth finish so that it can be photographed for display.
Note: Safety should be employed throughout the whole process in the form PPE. (safety glasses, ear plugs and safety masks)
This tutorial should provide you with a thorough step by step method on how to manipulate aluminium to form the shape of a 3 dimensional teardrop.
Step 2: Use a scribe and ruler once again to measure a piece of metal that fits on top of the stencil we The metal should be about 50mm more on every side to allow for shrinking and expansion.
Then cut this piece on the guillotine.
Step 3: You and your partner must select the template of a teardrop that you want to use. There will be a selection of over 30 teardrop shapes. These templates will be created and cut using the CNC laser cutter in the backroom of the workshop.
Step 4: You and your partner take turns to do your own job so take it upon yourselves to help each other when necessary. The CNC cutter left little tabs on the cut so that it would not fly off while cutting, therefore with a bandsaw, cut the little tabs were cut to create a perfect template of a teardrop on both pieces created, as you will receive two copies of the template.
Step 5: The metal sheet cut was placed between the two templates and screwed together together as accurately as possible to ensure the metal sheet within did not move or shift whilst being worked on. This is important as it can cause complications and errors in the overall design of the tear drop that can delay the process and ultimately create a defect in the end product.
Step 6: Using the white mallet, the metal piece within should be tapped gently using the sharp end to push the sheet down in to the space created. The goal is to create a downward curve to mimic the shape of a three dimensional teardrop. This process should be repeated until you can not hammer anymore due to the fact that you will reach the workbench below which would make the tear drop begin to form a flat surface.
Note: it is extremely important that heavy hitting is not used as any little mistake can alter the finish product, therefore you should also use a variety of other hammers and objects that fit the template, that allow for smooth work and minimal damage to the metal sheet. This will be in the form of a curved piece of timber being hit by the mallet as well as placing a smaller wooden mallet in the template and hitting it with the larger mallet softly and consistently in a downward motion.
Step 7: Then you will use small timber pieces, drill them into the bottom of the template to hoist up the overall job, thus allowing you to continue working on the teardrop with out it hitting a flat surface. You should aim to get the peak of the teardrop to go beyond the template by 5mm and end up getting it to about 15mm as shown.
Step 8: Equally measure from the centre to the edge on each side and slightly trim the edges so that the blister looks neat and tidy as well as accurate. This will allow you to begin the final stage of the project, finishing.
Step 9: The flat head hammer will be used slightly in this project to soften and straighten out any little bumps created but there should not be many as no sharp or metal objects should be used directly on the blister.
Step 10: Finally the job should be sanded both in the workshop and if necessary also at home to create a smooth finish so that it can be photographed for display.
Note: Safety should be employed throughout the whole process in the form PPE. (safety glasses, ear plugs and safety masks)
This tutorial should provide you with a thorough step by step method on how to manipulate aluminium to form the shape of a 3 dimensional teardrop.
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