Newbie- Getting started, how would YOU make these?

[LeeWay]

Now I was curious about something. Can you emboss with a cnc mill or router? I would think so. Using a couple different sized tools, you could theoretically emboss pretty darn elegant designs. Multiple passes. Softer material like a cutting mat or something underneath. Maybe even rubber.

Crap! I think i may have just given myself something else to try out, WHEN I GET TIME.

[One of Many]

Originally Posted by LeeWay Now I was curious about something. Can you emboss with a cnc mill or router? I would think so. Using a couple different sized tools, you could theoretically emboss pretty darn elegant designs. Multiple passes. Softer material like a cutting mat or something underneath. Maybe even rubber. Crap! I think i may have just given myself something else to try out, WHEN I GET TIME.

Well sort of and I don't see why not. There was a youtube video of a spinning mandrel running over a sheet as the die was raised from below. Not exactly efficient, but if power is work done over time, it did form metal.

Youtube metal forming

Youtube metal forming

[LeeWay]

That is cool. Similar to what I had in mind, but the other directions and not near that deep. I wasn't thinking about spinning the tool either. It seems they are still using a dies from below.
I think you would have a very tough part if that is stainless they are doing that to. Likely pretty hard regardless.

To do the embossing like I was thinking, it might actually need a spring loaded tool. Maybe not. I think a vacuum hold down might work best too.
A small pallet could be made up for this purposely though. I am sure some trial and error would be needed, but I do think nice results could be achieved like this.
Could be done on a mill or a router. I think I am talking myself into trying it out.

[ViperTX]

Well since you're working from the backside....I believe it's called Repousse (sp?)...So, you need a slightly resilient surface....well actually the surface must deform and stay deformed otherwise it would push back and distory your panel and the design. Years back pitch was popular...not sure if they have some similiar that is more up to date.

[One of Many]

Thanks Viper. I knew there was another name for the hand process, but I couldn't come up with it for noth'n.

Leeway,

Notice how rigid the machine that is forming the sheet and how the sheet is clamped in a frame? The die does come up from under the sheet each pass so there is very little Z motion of the spindle. The material is being stretched at the point of contact only. I cannot imagine vacuum of any benefit. At least for the Posters picture frame since there is nothing symetrical about that surface. I'd expect the sheet to contort all over the place as pin pointed material is put in tension to achieve elongation at the forming tool. With a slim possibility of having first cut the die profile, then using that cut path or geometry to step down a forming tool in similar fashion to the vidio clip. Keeping all the tension in balance? Pretty slow though!

I think, if'n it were my project. I would rather use low temp metals and cast the mold, polish then press. I must be losing that artisan patience in my old age! LOL!

DC

[LeeWay]

I understand how the video was working. Heating locally to stretch the metal and the die would move up.

The end result I was thinking of is more a bas relief.

Repousse would work as a term for it as well. Chasing too.

The end result would be a design that stands out from the surface. Much the same things as the 3D drawings that are carved away, instead of carving, this is bending to create a 3D image or surface. From both sides if wanted.

I did a few bas reliefs before by hand. We were using heavy gage foils. I am thinking if you use like .010" thickness sheet, you would have enough metal there to form such a 3D image.

Since it is bending locally, it may not distort the entire panel. Therefore vacuum hold down around the perimeter may just work. I am sure trial and error would have to be done.

I do have the parts I was going to use to start trying some aluminum casting. Just haven't needed to try that out yet in earnest.

[blackbeard52]

Maybe another approach...I had some experience with a 2 part resin casting company a few years back. We mixed brass powder in the resin and buffed the finish after molding couldnt tell the difference in the cast and original except for the cost. molds were made from silicone. took about 5 minutes to cast. As for thickness and details of carvings or stampings....perfect. The supplier showed us bird skeletons made from this material and the details were excellant and paper thin. The archelogical restorers use these resins to replicate Dino's in museums so the applications

[Rees Guitars]

I've handled some of the old tintype style case mattes before and they are reaaaally thin, barely thicker than foil.

I'd say you could get by with one aluminum die and a firm but flexible material on another flat die to press the brass into the recesses.

Hope the pic helps.

-Ed