-
- Tooling
in Copper, Brass, & Aluminum
-
Tooling is the
process of creating designs in sheet metal by emboss drawing,
stamping, denting, piercing, rub-transferring, folding and hammering.
-
- Copper has been
a metal of choice since the bronze age as it is soft and stretchable,
it takes impressions well and is less expensive than the other
soft metals such as gold and silver which have similar tooling
properties.
-
 Brass which is
an alloy of copper and zinc which, while being a bit stiffer,
tools well, is more tarnish resistant and has a wonderful golden
color.
-
 Aluminum is a
newer addition to the tooling metals. Even though it can be very
soft it doesn't stretch as much as copper but works well if care
is taken.
-
- The easiest metals
to hand tool are thin and conform to shaping and embossing with
little force. The most common thickness is .005 thick also known
as 5mill or 36 gauge. It cuts easily with a scissors or utility
knife. Of course, thicker metals can also be tooled with the
use of greater force, mechanical presses, etc.
- The 36 gauge is
much thicker and stronger than household foil. Standard household
foil is more than 7 times thinner at .0007 inches thick.
-
- Tooling metal
is shipped in a roll. If necessary ripples or curves can be flattened
by rolling it with a smooth rolling pin or plastic pipe section
on a completely smooth surface such as a countertop or glass
table. The tube we ship our craft metal in works well too!
-
 Drawing into the metal can be done to create
a impressed design which becomes a raised design on the other
side. This is done by placing the metal on a soft surface such
as a foam or rubber sheet or a stack of newspapers and firmly
'drawing' into the metal with a blunt tool or or 'stylus'. (shown
above)
-
- The
pointed and blunt stylus shown are for drawing, the flat spatulas
Shown are for flattening and the curved tool ends are for raising
metal.
-
- The capped end
of a ball point pen works well to start with. A bit of experimentation
with technique, different styli and pressures will yield and
infinite variety of results. Drawing tools should be blunt so
as not to cut through the metal. Such designs on copper are also
referred to as "Copper Relief". See below for step by step instructions
-
-
-
- The finished piece
can be easily colored or darkened with prepared patinas. A similar
effect can obtained with paint or stain that has been brushed
on and
 then wiped off. Subsequent
buffing of the high lights with an abrasive pad can give and
'antique' look. Work in thin foil can easily be cut and trimmed
with a scissors or utility knife in preparation for mounting
or framing.
-
- As a piece is
worked it will become stiffer. High relief that may be easily
dented was traditionally filled with plaster or pitch from the
back. A nice modern substitute is hot melt glue. Even Wax will
work if it is not placed in the sun or a hot place. Acrylic paint
poured thickly or in several layers on the back and allowed to
dry for days works well and is a great way to use up scrap paint.
-
- Photo
at right: A raised copper creation - Don Quixote by L.Henke
-
-
-
 Stamping, punching
and piercing are similar techniques in that they all involve
striking a tool against the metal with a mallet or hammer. Stamping
leaves only and impression while punching and piercing leave
a hole. The most familiar manufactured stamps for metal are for
impressing numbers and letters. With a little searching, tools
that will create many shapes and designs can easily be improvised
from objects around the home or garage. Early American lanterns,
boxes and pie safes had intricate stamped and pierced designs
created using only a screw driver and awl. Again, experimentation
will yield a wealth of possibilities.
-
-
-
-
-
Photo
at left: Steel number stamping. (Stamp set shown in first photo)
-
- Rub-transferring
is a great way to add a texture or an image to the tooling metal.
For example the image of a coin placed under the copper sheet
can be transferred by rubbing or burnishing the metal over the
coin with a rounded tool (the pen cap works well here as well).
Raised images and textures can be found everywhere around the
house and in nature. The amount of pressure required to obtain
a successful transfer will depend on the fineness of the individual
image or texture that you are transferring.
-
- Folding is another
possibility for creating lines or creases in tooling metal. It
is possible to recreate simpler origami designs in copper foil.
Sharp creases or folds have to be rubbed, hammered or burnished
along the fold.
-
- Hammering or Repousse (pronounced
rep-o-zay) is the process of repeatedly denting the metal with
a dome shaped hammer from the back in order to created a shape
in high relief. Hammering can be used to some degree on thinner
metal but care has to be taken as too much working makes the
metal hard , brittle and likely to perforate. The pebble-like
texture from repeated hammer blows can be burnished out by forcefully
rubbing it with a
 hard rounded
object. A small wooden ball or knob works well. Thicker metal
is used on larger pieces and can withstand a lot of hammering.
Once the thick metal becomes brittle, it is heated to red hot
and quenched (this is called annealing). The statue of liberty
is one of the most famous examples of this and is comprised of
many French Repousse components riveted to a steel frame.
-
-
- STEP BY STEP
BASIC TOOLING:
- 1) place tooling
metal on a pad or stack of news papers.
- 2) place pattern
(if any) on top and trace outline of design. (tape if necessary
to hold pattern in place)
- 3) remove pattern
and turn over the metal on pad.
- 4) Raise inside
the design starting from the edge and working inward. This stretches
the metal out from the back. Best done with rounded blunt tools,
then use whatever tool gives the texture desired.
- 5) Turn metal
over again and flatten background down by starting with the edge
of the design working outwards.
- 6) Mount, frame
and finish piece as you wish.
-
-
-
- EMBOSSING
METAL WITH CHILDREN:
- PLEASE USE
CAUTION when using raw metal especially around children. The
sharp edges can cut . (much as a paper cut) Wearing gloves will
minimalise cuts.
-
- We do not
sanction the use of these metals with children. By nature these
metals could not be offered any other way.The metals are created
& packaged for adult crafts persons and not sold as "kids
safe". If you have doubts please use heavy household foil,
which although is several times thinner than our foil is inexpensive
and safer.
|