A Designer develops a polygonal model, considering more than just standard requirements to anatomy and layout. It is important while developing such models to keep all polygons perfectly straight and avoid small angles in the bend lines. The completed model is sent to a technological engineer who creates blueprints considering specific performance features of the metal sheets.
In addition to the blueprints, included in the package for assembling models out of metal are:
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DXF file for laser cut and engraving;
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PDF file with specified bends angles;
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PDF file with the detail locations.
The differences between the blueprints for assembling models out of metal and paper are:
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Shape of polygons. The drawings developed for metal and paper are prepared with different software. For metal models we take a specific sheet thickness — 1.5mm. We take into account distortion and displacement which are related to the thickness of the material, stretching the radius of the bends. Polygons made out of paper can be bent on different planes and the facets have a place for applying glue.
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Size of the details. For metal models we use several neighboring polygons, creating small details. It is convenient when working with the rolling-and-bending machine. When working with paper, the fewer places for gluing the better. That is why the details are bigger and consist of numerous polygons.
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Assembly method. It is very hard to cleanly weld on inner bends, which is why we place the majority of the welding stitches on the outside. Gluing paper parts requires pushing the pieces together, which is why it is more convenient to locate places for gluing on the inner bends rather than on the raised spots.
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Locating blueprints on the model. The blueprint for metal is located on the face side of the model because we account for different types of metal. If the model is being constructed out of glossy stainless steel, then laser cutting should be performed on the glossy side (otherwise it will get scratched by the table surface). For paper models, the blueprint needs to be inside of the model so it is not visible after completing the sculpture.
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Sheet and file format. For production out of metal, we use the most common size of sheet, 1.25m x 2.5m. The format of the file for laser cutting is DXF. In the package there is also a file with the angles of bends for the rolling-and-bending machine and a PDF file with the location details. For production out of paper, we use sheets of paper A4, a PDF file, and an instruction with illustrations.
For constructing a hand-made sculpture out of metal you will need:
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Welding machine;
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Tools for working with metal (hammer, angle grinder);
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Personal protective equipment;
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Vise, welding clamps, and welding magnets if needed.
How to assemble the model
- Cut the pieces out of the 1.5mm thick metal sheet. It is better to cut the pieces using machinery with computerized control. Use files in the DXF format. We recommend using laser cutter, but you may also cut out the pieces manually. To do so, print the DXF files on paper — you may do it in a print shop. The paper is similar to regular office paper, but there are rolls of different width. The width needed to roll can be found in the description files on our website, where the number of the list is specified. The printed diagram will be a stencil for cutting pieces out of the metal. Printed details need to be cut, glued to the metal sheet, and cut with an angle grinder.
- Mark the bending lines and the numbers on each piece. You can do it by engraving, as there is a separate DXF file for this. The engravings will appear on the face side of the sculpture. You may also use a permanent marker after you cut the pieces out.
- Bend the pieces. You may do so using a roller bending machine or manually using a protractor, vise, and clamps. To simplify the process you may make pre-cuts with an angle grinder.
- Assemble the model with tick welds. Make sure that all pieces adjoin together.
- Weld together the major seams. For the convenience of cleaning of the hard-to-reach places, you may divide the model into separate parts. After you have assembled the model on the tick welds, determine the seams that you will separate into parts and do not weld them together. Weld only the major seams. Separate the model by the determined parts, cutting off the tick welds. Weld together the seams in the hard-to-reach places and assemble the parts of the model.
- Final touches. They are completely up to your imagination. Some may prefer rough seams and corroded metal, others — ideally polished and coated surfaces. Our Instagram page can help you with the decision of your finish. See the works of different professionals using the hashtag #pp_metal, where we share their work. Please use the same hashtag when you upload your own work.