Jewelry & Metal Arts


Foldforming

Foldforming

Foldforming Tools

Foldforming is a metalworking technique developed by Charles Lewton-Brain, known for creating three-dimensional forms through a combination of folding, forging, annealing, and unfolding metal sheets.

🛠️ Essential Tools for Foldforming:

Foldforming

Foldforming Resources

Foldforming is a metalworking technique developed by Charles Lewton-Brain, known for creating three-dimensional forms through a combination of folding, forging, annealing, and unfolding metal sheets.

📚Books and videos

PMC

PMC

PMC Precious Metal Clay

Requires very clean workspace and toolkits.

Due to the expense of working with Precious Metals - Bronze or copper clay is recommended for starter projects.

Dial Height Gauge

A dial height gauge is used in metalworking and precision machining to measure vertical distances from a reference surface—typically a surface plate, which is the large, heavy, flat round metal plate it's standing on in the photo.

Primary purposes of the dial height gauge:

  1. Measuring Height: It measures the height of objects or features with high accuracy.

  2. Scribing lines: When fitted with a scribe or scriber instead of a dial probe, it can mark precise horizontal lines on a workpiece.

  3. Comparative Measurement: It can compare the height of different parts or features to ensure uniformity.

  4. Precision Layout Work: Common in tool and die making, it helps in laying out precision measurements on metal surfaces.

The dial indicator on it allows for highly accurate readings and can detect very small differences in height.

 

39E4AAAE-CD41-4C2E-AC41-6A09CB50D6E1.jpeg

Wire Wrapping

Chasing and Repousse

Chasing and Repousse

Chasing and Repousse Tools

Pitch Pots
Repousse
Chasing

Needs Safety training

Enameling on Copper

Enameling on Copper

Torch Fired Annealing on Copper

Enameling on Copper

Kiln Fired annealing on Copper

Cutting and Forming Copper Sheet Metal

Cutting and forming sheet metal can be done with shears, Disk Cutting tools are for cutting and forming copper Sheet Metal and are often used in jewelry and small metalwork.
Here's a breakdown of how to use some of them on copper sheet metal:

Burrlife or Beeswax for lubrication of cutting surface
Steel Block as work surface, not wood.
Heavy Brass Mallet
Disk Cutters, Bevelled end up - the cutting side of the punch is a flat smooth surface.

1. Disk Cutter (circular tool with round holes)

This is used to punch out perfect circles of metal.

Steps to use:

  1. Anneal your copper (heat it to a dull red and let it air cool or quench in water if it's safe—wear gloves).

  2. Place your copper sheet between the plates of the disk cutter.

  3. Select the punch size that fits the hole.

  4. Align the sheet so the desired area is under the hole.

  5. Insert the corresponding punch into the hole.

  6. Use a heavy brass mallet or an arbor press to strike the bevelled end of the punch. It will shear the metal and drop a disk through the bottom


    🛠️ Proper Usage Tips

    • Insert the Punch Correctly: Always insert the flat, sharp end of the punch into the corresponding hole of the disc cutter, ensuring it makes direct contact with the metal sheet.

    • Strike the Beveled End: Use a heavy mallet or hammer to strike the beveled end of the punch. This will drive the sharp end through the metal, creating a clean cut.

    • Avoid Reversing the Punch: Striking the sharp cutting end can damage both the punch and the disc cutter, leading to poor cuts and potential injury.

    Quick Reference: Using Disk Cutters on Copper

    ✅ Anneal copper before cutting (heat to dull red, then cool).

    ✅ Use a heavy mallet or arbor press for clean punches.

    ✅ Lubricate punch tips with Bur Life or beeswax.

    ✅ Always place cutter on a steel block, not wood.

    ✅ Align copper and punch carefully—no tilt.

    ✅ Check punch sharpness regularly.

    ✅ Use correct gauge copper (20–24 gauge ideal).

    ✅ Remove stuck punches gently by flipping and tapping.


    Disk Cutter Troubleshooting Guide

    Issue

    Cause

    Solution

    Cutter won't pierce copper

    Copper is too hard (work-hardened)

    Anneal the copper before cutting

    Punch doesn't go through

    Not enough force used

    Use a brass/rawhide mallet or an arbor press

    Punch gets stuck

    No lubrication / tight fit

    Lubricate punch with Bur Life or beeswax

    Ragged or uneven cuts

    Copper or punch misaligned

    Ensure copper is flat and punch is vertical

    Noisy, ineffective cut

    Cutter not on solid surface

    Place on a steel bench block or anvil

    Won't cut thicker sheet

    Gauge is too high for tool

    Use thinner copper or alternative tools

    Punch not sharp

    Edge dull or damaged

    Sharpen or replace punch