Week 15: tutorial for the metal blister

THE BLISTER TUTORIAL
BEIL0014 – DIGITAL MAKING

Before creating the metal blister, it is strongly suggested to watch a tutorial video from the Youtube - Metalshaping tricks # 5, which it will help to understand the process and provide a outline for the creating steps:

Steps:

1. Creating the frame

2. Cutting the sheet

3. Shaping the deep

4. Finalising the blister

Step 1 - Creating the module

The based module made by MDF board should be draw and cut in following the specific outline by course tutors before the class. Two people would be a small group to create a pair of metal blister shape within two weeks, which the metal shape to be creating in the first week, and the second week should be left for adjusting with the group mate.

To creating the round shape in the middle, two tools should be carefully used into this process, which they should make the shape easy to cut and achieve smooth edge for later process - jigsaw, sander and. The jigsaw can simple and quick to cut off the middle shape following the outline of the shape; the sander will be able to enhance the edge of inside of shape smoother and no shape edge for the blister; while the drill could help the create at least four holes in each corner of the square base module, which it is for the nails to hold the metal sheet later in the middle.

jigsaw

sander

drill

Important note: if you do not know how to use any tools in the workshop, just ask the tutors or staff in the workshop.

Step 2 - Cutting the sheet

After the base frame is ready, we can use the guillotine in the workshop to cut the metal sheet to small square piece (the guillotine only can cut metal and plastic sheet). Draw the line firstly on the sheet and ensure a square shape should be drawn correctly, then just cut it with confidence!!!

Step 3 - Shaping the deep

When the metal sheet and MDF frame are ready for further action, the blister would be started to create by different types of hammers. Round edges of plastic hammer should be hold into the middle shape area, then the flat plastic hammer to hit the round plastic hammer. in terms of ensuring the deep balance for the entire eggshaped flange, large side of round plastic hammer for curve side of hit area, while needle side of plastic hammer for sharp area to hit, and do not hit one place only, but hit evenly for everywhere to avoid wave surface.

During a long time of hitting, the depth of the egg-shape should start to show up, which make the flange clearer and sharper. When the blister is deep enough, it is the time to release from the frame to develop the rest part. Also, the curved iron shape would be able to amend some small wave surface by hitting the blister on it.

Then, the blister is finished at 70% of entire process, using the chisel on the iron hammer to sharp the edge for the blister.

Step 4 - Finalising the blister

In the second week, the group mate should also finish the blister as well; hence, two blisters would be able to put together to check whether it is a perfect pair.

The final step will be to cut off the extra part of the blister. It could be leave less than 20mm for the edge surrounding the shape. The iron compasses will be a good tool to draw on the metal sheet instead of using any pen or pencil because it is to leave a mark and easy to follow to cut.

It could use the metal scissors to cut the extra part, but it would not be easy since you have to put some strength on it. There is a small tip: using the guillotine of step 2 to cut off large area then the "big scissors" in the workshop to cut the small and curve part, it is feeling like to cut a piece of paper. (Asking staff or tutors before using !!)