Modeled Material: 1 sheet of 18 Gauge Bronze, 5″ x 5″
Die Material: 2 pieces of 3/4″ MDF Lite, 6″ x 6″
Design: Modeled in rhino. One surface was designed from a series of lofts through geometric shapes. This surface was used to describe the positive die form. This surface was then offset to 1.5 x thickness of my bronze sheet before it was used to describe the negative. The offset accounts for the thickness of the bronze as well as a good amount of tolerance to prevent my die forms from undergoing too much pressure.
Production Process: Bronze sheet was annealed, quenched, dried off and placed between both dies in a hydraulic press. Care was made to ensure both sides of the die form aligned throughout the pressing process. The press was cranked until both sheets of MDF met in a closed seam.
Notes for improvement:
Better options for larger production runs would be polycarbonate, hard plastics or hard woods. MDF tends to round out the details or break off in high pressure.
Some form of registration might be helpful so that both sides of the die close in the right place instead of having to align it by eye.
Details of Project:
Name: Justin Lin
Date: October 2012
Class: Advanced Metals, taught by Carol Kumata