STEP 6: Metal Shaping Second Part Final step

 Metal Shaping Second Part

 

For the last part of the shaping model, you also need to measure the size of your template and draw it on the metal.

Make sure the size are correct and after that you can start to the next step.

To make a negative space on the surface, First is to mark the area that you need to tap on and find a tool that has U shape hole to put below the sheet metal, so that you can hammer the shape with a round tool to tap on. Remember to tap the three peaks of the triangle, that will make the work easier to control. Then tap the left over part of the area.

To pull up the middle shape( the triangle part in the middle ), it is better to cut a tool that has the same shape, find a 5mm plywood board to cut the shape, and you need to measure the size of the triangle and draw it on before you cut the shape.

Using the cutting machine to finish your tool.

First you need to dig a hole in the middle to make it hollow that create a space to put the cutting line in. So that you can easily cut the middle part of the wood board.

Cut the outside line on the board, after cut out the middle part.

Use the sander machine to round up the edge of your tool. Move the wood board slowly to provide the board will spread out from your hand.

Tape the edge of the cutting line, to stable your tool. Try to fit on the triangle shape notch.

Put the wood triangle tool below the sheet metal and tap it with hammer to make the surface flat, tap the edge around the triangle to make the shape of the side match the tool below.

Turn to the other side of the sheet metal and use the round edge tool to tap the negative space. Repeat the last step and this step to make the hole more smoothly. And try to put the metal sheet on the 3D template to make sure it fits on the surface.

Use the cutting tool to cut out the extra space.( You have to cut it after you finish tapping the metal because metal will extend when you tapped it and the size might change if you cut the shape first )

Spruce up the cutting line to make it smooth.

Use the steel hammer to tap the edge of the metal, to provide some shark lines will hurt yourself.

Fold the part of the speaker side into 90 degree, by using the folding machine.

The last step is to smoothen the top and bottom edges with the tool.

The side view of the speaker.

Front view of the speaker.

Side view of the final model.

Two part of the metal can match to each other.

Front view of the whole final model.

Make sure the side metal part can fit into the wood template.

STEP 5: Metal Shaping First Part

Metal Shaping First Part of the model

First step before starting to cut the metal into smaller size that match your 3D model template size.

To measure up the size and draw the line on the metal that you can cut it correctly.

Curved the shape of the metal to fit the actual 3D model (The surface of the speaker is curved).

Before to beat the metal into right shape you can make a tool that the form are same as your model surface shape.

When using the cutting machine you have to be careful and move the wood slowly and smoothly to make sure the shape of your tool.

Double check the shape that match your 3D model.

When you prepared all the shaping tools, start drawing the area that you may tap on.

Put your sheet metal on the wood tool that you made before, and start beat the metal by using the hammer.

Check every time when you tapped the metal. To make sure your metal match the shape.

The side view when tapping the metal.

Keep tapping to make the metal shaped like the 3D model template.

Look at the side of the sheet metal, and check the curved shape and the edge.

Try to fit in the template that you made.  In this step you may found out that some part of the sheet metal are not actually fit in. So you have to check every part and edge of the metal that you made.

For example, the curve shape are not fit in the template, so I do the cured surface again.

Put the sheet metal on the template and tap the surface of the metal by using the hammer. After all steps that you follow. Then you can get to the next part of the metal shaping model.

STEP 4: Complete Laser Cut Template

Complete Laser Cut Template

 

Setting up the details for laser cut template layout 

change the size of your paper to fit your material board.(900mm x 600mm)

 

Red lines (cut) 

  

Blue lines (mark the numbers on the surface in each sections)

To be laser cut on 3mm Plywood board.

Ready to laser cut, first to send the ai files to the computer which links to the machine.

 

Laser cutting the 3mm plywood board

 

Fit in all the waffle board to finish the construction 3D model template.

 

 Follow the number on the surface will be easier to do.

It is better to glue each pieces to build the structure more stable.  

  

STEP 3: Create the waffle section for Laser Cut

Create the waffle section for Laser Cut

First you have to import the stl files into 123D Make app.

After import the file, in 123D make we can complete a laser cut template for your 3D model by cutting the sections.

 





In this step you have to set up all the details including the thick of the material board, the type of the construction of your final model. And the section form of your laser cut pieces. 




Change the scale into "mm"(same as the thick of board you chose) , then select the size that you wanted to chose. I recommend that to choose a larger template cause it will be easier to do the sheet metal work if the template is bigger.And you can do more details on the sheet metal.

Choose the construction of your model by selecting the " construction technique" on the left tab. It has five different type of construction, you can choose the most likely one you think is the best to the laser cut step.

Then go to the " manufacturing settings" to fill in the size of the material board that you use in laser cutting steps. If you want to do more details in your 3D model you can choose 3mm thick board or less than 3mm (The material board that I used is 900mm x 600mm x 3mm plywood board ) 
In order to fit in the layout of the laser cut machine.

Save the files in dxf for the laser cut step after all the details are set.

And export the file with laser cut layout.