Hydraulic Die Forming Discussion Group
Sequential Embossing & Matrix Die Forming

Jack Berry
berry2000@prodigy.net

I was looking at some work I had done some time ago to come up with something that might be suitable for Phil Poirier to possibly use in his Santa Fe Symposium presentation. I thought I would share this with the Discussion Group because it is a convenient way to use embossed wire elements and do die forming with the same die. Attached are 3 examples and an image of the die used for the top left piece. The relative sizes are not accurate due to the "squish factor" in getting them on one posting. A drawing of the piece is glued to the die blank and the 3 lobes are cut out and SAVED. The saved "plugs" are placed in the openings, the prepared wires are lightly glued in place on the drawing, the sheet of sterling is placed over the wires and taped in place with small pieces of vinyl tape (it stretches and is easily removed) and the embossing is done. The plugs are removed without disturbing the wires and sterling sheet, the urethane is changed to a thicker pad and the die forming is done. The piece is trimmed and the wires are easily soldered into place, each having a custom "nest" to support them (and identify them even if they are close in shape). A framing wire and finding on the back were then added. A series of these pieces were made using the same die but using different shapes and number of wires, shorter wires with a stone set in the central area and using the opposite side of the die (giving a mirror image shape to the piece).  In the lower left piece the central cut out area of the copper sheet was also saved and temporarily returned to its position while soldering the brass wires because the "nests" were too short to support the wires by themselves. Happy Holidays everyone!!  ....Jack

Sequential Embossing & Die Forming

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