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The Blister

The Blister -

The Fourth and final task to Assignment 1 was to shape a flat square piece of aluminium so it would have a protuding blister by using a CNC cut mdf template.

Material:
  • Aluminium sheet
  • MDF 18mm thickness
  • 4x screw and bolts
Tools used:
  • Screwdriver with 7mm drill bit 
  • Nylon mallet 
  • Disk Sander
  • Router
  • Scrap wood 

Step 1

The first step was to gather the material needed but more importanly a CNC cut woodn template for the blister. A small hand router was also used to remove the excess infill from the wooden template. Next step was to cut the aluminium sheet to fit the size of the wooden template.

Step 3

Using the drill in pair with some nuts and bolts the aluminium could be sqaured up inside and screwed tightly into place, ensuring it was taught and didnt move freely.



Step 4

Now the fun bit. The plastic mallet was first used to begin the stretching of the aluminium to achieve the first level of depth for the blister. The hammering pattern required you to be consistent and even with the direction of stretching, in this case I would hammer in a line in the y direction whilst making small movements in the x direction after each complete sweep in the y axis. It is to note that the plastic mallet cannot reach about 60% of the metals surface due to the height of the template and thickness of the mallet, this is why various thinner corking tools were needed to complete the job. The beauty of these tools was it could be easily modified on the disk sander to achieve the desired angle needed for hammering. 






Final results from the hammering



Step 6 

Sand and polish for a smoother surface finish.

Final Pictures




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