Tutorial 2-Brick

PHASE 1- DIGITAL MAKING and PHASE 2 – LASER CUTTING is pretty much the same as the tutorial 1

TIPS: For the LASER CUTTING, try 'Interlock slices' construction method instead of 'stacked slices' for saving materials, but it might also compromise the stability of the template 



PHASE 3 – METAL SHAPING

Step 1- Cutting the metal sheet

1. Using the Guillotine to cut the aluminium sheet and get a proper size for the template. In my case, I used 20x20cm sheet

2. Use the large shear or the aviation snip to cut the metal off

Step 2- Shaping the metal sheet

1. Use the sandbag and Bossing Mallet to hit the marks on the sheet, because the sandbag can be adjusted, so adjust it in a good shape to support the metal sheet

2. Find a flat surface and overturn the metal, use the Barrel Mallet showed above to hit the peripheral towards the center in order to narrow the hole. Keep doing this, then the gap between will become smaller than previous

BEFORE-LARGE GAP

AFTER-SMALL GAP

3.Hold the metal in the position against the tapered T-Dolly showed above, then hit the metal to refine the depth. Find any sharp tool if you can to apply the same method

4. Because the middle part suppose to bend inward, so use anything you can find to support the side part. This is the way I found to support it and use the Bossing Mallet to hit it

5. Refine the edge and surface by using small hammer