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DieForming
HydraulicDieFormingforEnamelists
byCarolHoladay
fromVol.18,No.1,April1999
SpringPromise
Introduction
Thepurposeofthisarticleistopresentafewbasictypes
ofdiesthatcanbeusedwiththehydraulicpresstoformmetal
in preparation for enameling. I have included a brief
overview of hydraulic die forming for those not already
familiarwiththisprocess.
I am an enamelist, jeweler and teacher. As a part time
instructoratMontereyPeninsulaCommunityCollege,Iteach
Metal Arts I & II, Introduction to Enameling (basic to
advanced techniques) and a variety of specialized short
courses such as Die Forming and Enameling. Along with
Susan Kingsley, I have co taught workshops at Arrowmont
SchoolofArtsandCrafts,includingoneatthelastEnamelist
Society conference. Susan covers the hydraulic press
instructionandIcovertheenamelingportion.
First, I'd like to say that everything I know about die
forming (and share here with her permission) I have learned
from Susan, a good friend, outstanding artist, inspiring
teacher and the author of HYDRAULIC DIE FORMING
FORJEWELERS&METALSMITHS.
If you are considering building or buying a press, I
stronglyrecommendthatyoureadthisbookfirst.Therearea
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number of safety issues to be aware of, and much more
informationregardingdieformingthanIcouldpossiblycover
inthisshortarticle.
AGreatToolforEnamelists
Thehydraulicpressisagreattoolforenamelists.Withthe
press,afewtools,andsimplediesthatyoudesignandcreate
yourself,youwillbeabletoeasilyformmetalinpreparation
foravarietyofenamelingtechniques.Whenthingaugemetal
is formed, structure is given to the metal and results in the
metal being less likely to warp when enameled and adds
strengthtotheenamel/metalcomposite.
Giving dimension to flat metal
HydraulicPress
can be an important design element,
makingitmoreinterestinghowever,
whenusingtraditionalmetalworking
techniques, going beyond simple
forming can be labor intensive (as
withrepoussandchasing)andtime
consuming.Incontrast,onceadieis
made,itcanbeusedtoquicklyform
a number of identical forms.
Although
die
forming
has
traditionallybeenusedforproduction
work, artists making oneofakind
pieceswillfinditusefulforthemany
uniqueeffectspossiblewitheasyto
makedies.
The hydraulic press uses power
provided by a 20ton bottle jack (or
some alternative power source) and
theconformabilityofpolyurethaneto
gently move annealed metal into
and/oraroundthedie.Jacksoflesser
power can be used for some of the
techniques described here, but are not strong enough to
producefinedetailwhenusingshallowembossingdies.
AnAbbreviatedGlossary
COMBINATIONDIEtwoormoretypesofdiesusedin
combinationtoform,embossand/orcutthemetal.
DIEthetoolthattheartistcreatestoformthemetalinthe
press.
EMBOSSING DIE a die used for forming a shallow
relief in sheet metal. Can be made of wire, pierced metal,
carvedacrylic,etchedmetal,etc.
FLANGEtheextrametalthatskirtsashapeafterithas
been formed. It serves to clamp the metal between the die
and the urethane pad during pressing. It can be removed or
leftaspartofthedesign.
MATRIXthenegativeorimpressionpartofadie.
NONCONFORMING DIE a die with only one part,
eitheramatrixorpunch,whichisusedwithurethanepadsor
containedblocksofurethane.
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PUNCHatoolthatisdrivenintoasurface.
SILHOUETTEDIEasimplematrixdieconsistingofa
thick plate (of acrylic or other noncompressible material)
with the silhouette of a form cut out, used with a urethane
pad.
SPACER a block of noncompressible material
(Plexiglas, etc.) that is used to take up vertical space in the
press so that the hydraulic ram is not fully extended, this is
importantforefficientuseofthejack.
URETHANEatoughrubberlikematerialthatbecomes,
under pressure, the other half of a nonconforming die.
Available in two degrees of hardness (durometer), and in a
rangefrom1/16"to1"thick.95durometeristhehardestand
usedmostoften.80durometerisslightlysofter,movesunder
lesspressureandhasspecificuses.Colorsofpadsarenota
consistentindicatorofhardness.Markthedurometeronthe
pad with a permanent marker. Thin pads are used for
embossing.Thickerpadsareusedfordeeperforming.Note:
rubber is not a good substitute for urethane because it
compresses, whereas urethane moves (like water in a
waterbed).
SomeTipsandFactsforUsingthePress
ANNEALING Metal must be
Photo2
annealed before forming. If metal
cracks or splits during pressing, it
wasn't annealed properly or you
attemptedtopushittoofar,causingit
toworkhardenbeforeitcouldstretch
the full amount. Instructions for
annealing metal are covered in most
jewelry howto books. My own
preference is to use the kiln for
annealing, especially when I am
working on a number of pieces at
once.
URETHANEPADSTheharder,
thinner pads are used for maximum
detail. They should be used with
shallow embossing dies (including
simple wire dies and thin matrix
dies).Theycanalsobeusedforthe
firstpressingwithasilhouettedieto
assureasharpedgeontheform.Thicker,softerpadsareused
toproducethemaximumdepthofform.
THEJACKANDTHEGAUGEThe20tonbottlejack
maybemodifiedbytheadditionofagauge.Thisgaugedoes
not indicate how much force is actually being used or when
themetalhasbecomeworkhardened. Whatis measuredby
thegaugeisthepsi(poundspersquareinch)beingexertedby
the hydraulic ram. How many psi will be required for any
specific die and pressing cannot be predicted as there are so
manyvariables.Eachdieisuniqueinsizeandshape.Also,
differenttypesandgaugesofmetalwillaffecttheoutcome.It
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ispossibletoworkwithoutagaugeonthejack,butitisvery
difficulttojudgetheoptimumpressurebyfeelortoreproduce
exactresults.
Properly annealed metal should not require pressure
beyond8,000psi.Shallowembossingdieswillrequiremore
pressure than large silhouette dies. Some applications will
requirenomorethan1,000psi.Correctpsireadingsforany
applicationarerelativetoindividualjacksandgauges.(This
iscoveredinSusan'sbook.)
MAKENOTESofwhatworks,whatdoesn't.Whenyou
have determined the correct pressure and/or the number of
timesannealedtoachieveadesiredresult,makenotedirectly
on the die or on a sample pressing. This will save a lot of
wastedtime,metalandfrustration.
PRACTICEoncopperbeforepressingsilver.
TraditionalEnamelingTechniques
Following are a few examples of how die formed metal
canbeusedincombinationwithvarioustraditionalenameling
techniques:
BASSETAILLEInthis
technique, traditionally the
metal surface is textured
through a variety of means
including etching, engraving,
roll printing, stamping, or
hammering. Several thin
layersoftransparentenamels
are then applied over the
textured base. The use of
shallow embossing dies and
the press can be an effective
way to produce the low
raised planes that remain
below the surface of the
smooth enamel. The key
here is that the die forming
should be very minimal so
that the enamel surface is
flat.Darkertransparentswill
emphasizetheapparentdepth
and detail of the shallow
forming.
CHAMPLEVWiththepress,shallowmatrixorpunch
stylediescanbeusedtoformthecellstraditionallyformedby
etching, engraving, sweat soldering or repouss. Enamels
aretheneitherwetinlaidintothecells,leavingthehighareas
ofmetalbare,orsiftedovertheentiresurfaceandthenground
offthehighareasafterfiring.
CLOISONNIfwireisusedforthedie,narrowridges
will be raised in the metal sheet, which can give the
appearanceofcloisonnewireswhensurroundedby(opaque)
photo4
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enamel.Thisisakindof"fauxcloisonn"because,strictly
speaking,itisavariationofthechamplevtechnique.
COMBININGTECHNIQUESItispossibletocombine
variousstylesofdiestoformandtexturethemetalinoneor
more pressings. For example, areas of bassetaille can be
includedwithinachamplevpiece.
OtherUses
Complexshapescanbequicklydomedwithouttheuseof
hammersandtheirresultingmarks.Thissmooth"pillowing"
canbeshallowordeep,andtheedgesoftheformwillremain
flat this can be important for ease in bezel setting or the
creationofahollowform.
Die forming combines well with other metal working
techniquessuchasfoldformingandrollprinting.Additional
repouss can be accomplished easily with the use of hand
toolsoncethediehasestablishedthedesignthisresultsina
more"handson"appearancewhichcanminimizethe"hotoff
thepress"or"cookiecutter"look.
ThreeDiestoGetStartedWith
1.MATRIX(orSILHOUETTE)DIE
Thisstyleofmatrixdieissimplyablockofmaterialwitha
shape sawed out, leaving a void which metal is formed
(pushed) into. As used in this form, it is also known as a
silhouette die. Urethane, when used with a matrix die,
becomes the punch that pushes the metal. A silhouette die
can be used to form softly pillowed shapes for a variety of
enamel applications including traditional cloisonn,
Limoges,bassetaille,etc.
MakingtheDieSomeGeneralRules
A matrix die can be made from a variety of hard, non
compressible materials such as Masonite, aluminum and
acrylic sheet. Cast acrylic sheet is inexpensive and easy to
cut. A die cut from acrylic, when properly made, will
withstandconsiderableuse.
Asageneralrulethecutoutpartshouldbecenteredandno
closerthan3/4"totheedgeofthedie.Awidermarginwill
makethediebothstrongerandmoreefficient.
Widthof Thickness
Silhouette
ofDie
1" .............. 1/4"
11/2" .............. 3/8"
2" .............. 1/2"
21/2" .............. 3/4"
Thelargerthecutoutsilhouette,thedeeperthereliefcan
bepressed.Thedeepertherelief,thethickerthedieneedsto
be (refer to chart). Dies that are too thin for the design can
result in forms that have "bottomed out" (have flat tops).
Becauseitisdifficulttohandsaw1/2"orthickeracrylic,you
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mayprefertobuildupthethicknesswith1/4"layers.Make
surethattherearenoundercutsintheaddedlowerlayers,as
top layers will break if not fully supported. (Fig. 1) The
layersmaybebondedtogetherwithdoublesidedtape.
Figure1
StepsforMakingaSilhouetteDie
1. Transfer your design to an acrylic sheet. This sheet
usuallycomeswithaprotectivepapergluedtoit.ItisOKto
drawyourdesigndirectlyontothispaperiftheshapedoesnot
needtobeprecise.Formoreexactlayout,removethepaper
anduseascribetomarkalineintheacrylic.Fillthelinewith
apermanentmarkertomakeiteasiertosee.Anotheroption
istopainttheacrylicwithcoloredfingernailpolishandscribe
thedesignintothat
2.Drillaholewellwithintheshapetobecutout.
3.Sawouttheshape,usingaspiralsawblade(usedfor
sawing wax) set into a jeweler's saw frame. These are
difficultbladestokeepontruecourse,socutwithintheline
andtrimtothelinewithafile.*
4.Useacoarsefile(awaxfileworkswell)totrimupto
theline.Thewallofthecutmaybeangledsothattheholeis
slightly smaller at the bottom of the die than it is at the top
(Fig.1).Inotherwords,theopeningatthetopmustbefully
supported(noundercuts)topreventtheedgesoftheopening
from breaking from the pressure of the metal being pushed
intothedie.
5. Mark the top of the die in some permanent fashion.
This is the side of the die that is placed against the metal.
Hint: After repeated use, the edges of the opening may
becomerounded.Ifthisisadiethatisgoingtogetalotof
use,andtheedgesmustremainhard,firstcuttheshapeina
sheet of brass (16 gauge will do) and use this as a faceplate
overtheacrylic.Usethepiercedmetalasatemplatetomark
theacrylicandcutwellwithintheline.Iusethismethodfor
mostmatrixdies(evenwhenIexpectthemtohavealimited
use), because I can cut the metal more accurately and easily
than the acrylic. Very narrow areas will not need to be
removed from the acrylic, as the metal will not form deeper
thanthefaceplate.
6. If any area of the opening is wider than 1", you will
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needtocutasecond1/4"dieinordertoallowforthedeeper
forming that can be achieved in those areas. Identify and
markthefirstacrylicdiewitha#1anduseitasatemplateto
markthedesignonthesecondsheetofacrylic.Onceagain,
pierce and cut well within the line. Remember that the
opening in the bottom die needs to be smaller than the
opening in the top die so that the top die remains fully
supported. You will only need to cut material from the
second die in areas where the metal is being formed deeper
than the first die allows for. Mark this die #2. The two
acrylicsheets(andthefaceplateifyoumadeone)canbeheld
togetherwithdoublesidedtape.
UsingtheMatrixDie
GAUGEOFMETALMetalfrom18to28gaugecanbe
formedinmatrixdies.Thecorrectgaugeisdeterminedbythe
depthofreliefdesired.Thedepthofreliefpossibleisinturn
limited by the size of the cut out shape and thickness of the
die.Larger, thicker dies will require heavier gauge metal to
accomplish the desired form. The smaller, thinner dies may
beusedtoformthinnermetal.Thewayinwhichtheformed
metalwillbeusedshouldalsobeconsideredwhenchoosing
thepropermetalgauge.
SIZEOFMETALMetal
photo6
to be formed in matrix dies
should be at least 1/2" larger
than the silhouette cutout.
This flange may be cut off
afterpressingiscompletedor
trimmed and used as part of
thefinalpiece.
ANNEALED METAL
Metaltobeformedshouldbe
properly annealed. As the
metal is stretched by the
action of the urethane
pressingitintothedie,itwill
work harden. Ifyouattempt
to stretch the metal beyond
the point when it hardens, it
will crack and split. The
piece needs to be formed in
stages, and may require
several annealings and
pressings before it can reach the relief (pillowing) desired.
Beginwiththethinnerpadsandprogresstothethicker,softer
ones.Donotattempttomovethemetalagreatamountinone
pressing!
PLACEMENTOFMETALINTHEDIETheannealed
metal is sandwiched between the die and the appropriate
urethanepadandthis"sandwich"isplacedinthecenterofthe
bottom platen of the press. It doesn't matter if the die is on
thebottomorthetop,aslongasthemetalisinthemiddle!It
is advisable to use acrylic spacers below and above the
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"sandwich" in order to shorten the required length of
extension of theram. Thejackdoesnotworkwellwiththe
ramatfullextension.(Fig.2)
CHOICEOFURETHANEPAD,PSITOAPPLYBegin
with a thin hard pad and a (relatively) high amount of
pressure. This will establish a firm edge while forming the
metaltoonlyashallowdepth.Ifyourgoalisashallowform,
as it might be for a cloisonn project, this will be all the
formingthatisrequired.Ifyourgoalisadeeperform,then
proceed with successive pressings. Using a thicker soft pad
and very little pressure (start with 1000 psi), form the metal
part way into the die. Anneal and repeat, each time with
increasedpressure,untilthedesiredreliefisachieved.Ifthe
metal cracks or tears during pressing, you used too much
pressure, the gauge was too thin to begin with and/or the
metalwasnotproperlyannealed.
Figure2
2.MATRIXSTYLEEMBOSSINGDIE
Averythinmatrix(silhouette)diecanbeusedtoemboss
metal in preparation for use in the bassetaille technique of
enameling.Thelowraisedplanes(ordepressedareasifyou
use the reverse side), when covered in colored transparent
enamel, will result in beautiful dark to light patterns that
remainbelowthesurfaceofthesmoothenamel.Note:One
of the differences between metal that has been embossed in
the press and metal that has been roller printed is that
embossedmetalhasdetailonbothsides.
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Photo3
MakingtheDie
Thistypeofdiecanbecutfromthin(24to26gauge)sheet
metal, or any other noncompressible material of similar
thickness.Myownpreferenceistousesheetmetal,becauseI
find it easy to pierce, saw and refine my design using metal
workingtoolsandmethods.Thisdiecanbeusedfromeither
sidemakingitareversibledie.Etchedmetalplateswillalso
workiftheetchisdeepenough,andthedetailisnottoofine.
1. Draw a design with multiple small areas that will
becometheraisedareasoftheformedmetal.Youmightwant
tofillintheseareasofyourdrawingwithadarkmarkingpen
togetaclearerideaoftherelationshipbetweenwhatwillbe
cutawayandwhatwillremain.Bothareequallyimportantin
yourdesign,whichwilllookmuchlikeapatternforastencil,
withallofthebackgroundconnected.
2.Useawatersolublegluesticktoattachthedesignto
yourpreviouslycleanedmetal.
3.Pierceandsawoutthedesign.Fileandrefinethecuts.
Hint: Filing a slight bevel at the top edges of the openings
willhelptopreventthediefromgettingstuckinthepressed
metal.
UsingAnEmbossingDie
Thinner gauges of metal will emboss with greater detail
thanthickergaugeshowever,theenduseofthepressedmetal
must also be considered when selecting the gauge for any
project.Thingaugesofmetalmayrequirecreativeplanning
in the design stage, as they will be fragile and easily bent.
Testyourdieusing24,26,28and30gaugeannealedmetal,
and you will quickly see the difference in how the gauge of
metaleffectstheresults.
1.Annealyourmetal.
2. Using your thinnest, hard urethane pad and the
maximum pressure your press allows for, press the annealed
metalintothedie(seeearlierinstructionsformoredetails).
3.Optional:Afterthemetalhasbeenembossed,youmay
"pillow"formitinasilhouettematrixdie.Topreservedetail,
don'tannealitaftertheembossingstep.
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EnamelsfortheBasseTailleTechnique
In the bassetaille technique you will want to use
transparent enamels directly on the formed metal (without a
base of flux) in order to take full advantage of the shallow
forming.Mostcoolcolorsfirewellonfinesilverandmany
lookgreatoncopperaswell.Previousarticlesprintedinthis
magazinehavelistedtransparentleadfreeenamelsthatwork
welldirectlyoncopper.InmyowntrialsIhavefoundmany
more lead free colors (both cool and warm) that fire
beautifully directly on copper, too many to list here. You
should test your colors, building up the desired depth of
enamelwithseveralsiftingsandfirings,beingcarefultofire
tofullmaturity,justasyouwillonthefinishedwork.
3.PUNCHSTYLEEMBOSSINGDIE
This style of die can be
Photo5
used to formmetal foreither
the champlev or "faux"
cloisonne techniques of
enameling. Enamel can be
wet packed into the cells
created by the die, or it can
besiftedovertheentireform
andgroundoffthehighareas
afterfiring.
Inoneapproach,adiecan
be quickly and easily made
with round brass wire. The
wire die may simply be
placedontheannealedmetal
and pressed, or it may be
taped to paper before
pressingifthereareanumber
of loose elements. For a
more permanent die, wires
can be soldered to a thin
sheetofmetal.Areversibledieisonethatisnotsolderedto
abackplate.(Seebackcover.)Thisallowsforusingthedie
fromeitherside,andthecreationofreverseimagesasmight
bedesiredforapairofearrings.Shapescutfromsheetmetal
can also be used for this type of die, either in combination
withwireorontheirown.
MakingandUsingaWireDie
Iuse14and16gaugebrasswireformostofmydies.
1.Bendwirestoyourdesign.
2.Tape,glueorsolderwirestopaperorthinsheetmetal
as desired. If you are making a reversible die, solder the
wirestogetherbutnottoabackplate.
3.Useathin,hardurethanepad,andasmuchpressureas
yourjackwillallow,topushtheannealedmetalintothedie.
Remember that the thinner the gauge of your metal, the
greater the detail. I do most of my work using 24 or 26
gauge.
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Note:Themetalwillnotformasdeeplyintonarrowareas
asitdoesintowiderareasofthedie.Onasecondpressingof
thesamepieceyoumaywishtoadd"pushers"intheseareas.
"Pushers" are made from small pieces of thin urethane pad,
andarestackedovernarrowareasbetweenthemetalandthe
fullsizedpad.
Youmayenamelonthedieformedmetalasitcomesfrom
the press,oryou may choose to do some additionalforming
using repouss and chasing tools. I do this forming over
wood,andworkfrombothsideswithoutthemessofpitch.I
alsouseasmallnylonhammerwitharoundedfacetoslightly
dometheform.Therearewaystoembossanddomeinone
application,butthatisanotherarticle.
ToGrindEnamelOffofRaisedAreas
A variety of grinding
Photo7
stones, papers and diamond
pads or files may be used to
remove enamel from raised
areas of metal. My
preference is to use silicon
carbide belts on the
expandingrubberwheelsofa
lapidary unit. Beginning
witha320belt,Iprogressto
a 400 and then a 600 belt.
Finer grits can be used for a
higherpolishifdesired.Iuse
a glass brush under running
water to clean the piece
between belts and after the
finalgrindinganddon'tallow
the grinding residues to dry
intheporesoftheenamel.A
hard wax (I like Johnson's
Pastewax)maybeusedasa
finishovertheenamelandthemetal.
Equipment,ToolsandMaterialsList
Formakingandusingthediesdescribedyouwillneedto
havethefollowingitems:
hydraulic press with 20ton jack (preferably one with a
gaugeinstalled)
urethane pads (a minimum of two) one thin, 95 durometer
onethick,80durometer
spacersforpress
torchforannealingmetalandsolderingwiredies
1/4"castacrylicsheet(Ibuyinbulk,cutto4X4")
sheetmetal(brass)fordies,variousgauges
wirefordies(brass),14to20gauge
jewelerssawframeandbenchpin
spiralsawbladesforcuttingacrylic
sawbladesformetal
flexshaftorhanddrill
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drillbit{#55willwork)
waxfiles,smallandlargefilesformetaldoublesidedtape
scribe
permanentmarker
Optional:
repoussandchasingtools
chasinghammer
smallnylonhammerwithroundend
woodblocksforforminginto
*SafetyWarnings:
Any modifications made to a jack must be made by a
qualifiedperson.
Acrylic"sawdust"isverysharp.Donotgetitintoyour
eyes.Itclingstoyourskin,clothsandtools.Cleanupyour
workareaimmediatelyaftercuttingandfiling.
AddressfororderingSusanKingsley'sbook,
HydraulicDieFormingforJewelers&Metalsmiths:
20TonPress
P.O.Box222492
Carmel,CA93922
$25{includespostage)toU,S.andCanada
Californiaresidentsadd$1.45fortax.{sendacheckmadeout
to:20TonPress)
ForforeignordersofKingsley'sbook,contact:
Frei&Borel
18007723456
Othersuggestedreading:
TimMcCreight,
MetalsTechnic
BrynmorganPress,1992
TocontactArrowmontSchoolofArtsandCraftsregarding
workshops:
[email protected]
Websitestocheckout:
BonnyDoonEngineering{forpress,etc.)
http://www.bonnydoonengineering.com/
Robin Casady's site for images of my work as well as
SusanKingsley'sworkandatourofherstudio:
http://www.CarmelCoast.com/
Orchid,aforumforjewelers,metalartists,etc.
http://www.ganoksin.com/
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DieforLeafStand
Copyright2012,GlassonMetalMagazine
GlassonMetalisaregisteredtrademark
ofW.W.CarpenterEnamelFoundation
AllRightsReserved
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