Sheet metal is very easy to form, including the pressing in of intricate shapes with dies and a hydraulic press, but the dies themselves are slightly harder to come by. What if we could 3D print custom dies to stamp logos and more into sheet metal? This is the premise of a recent video by the Stick Shift Garage channel on YouTube in which dies are printed in PLA+ (solid infill) and used to stamp 1 and 2 mm thick sheet metal with the channel’s logo.
As can be observed in the video, the results aren’t bad at all after a couple of tweaks and adjustments to the pressure, but of course there is room for improvement. Some helpful commentators suggest improving the dies with properly rounded edges on the die’s shape and paying attention to K-factors and kin so as not to overstress or tear the sheet metal. In terms of die longevity, the PLA+ dies began to wear out after about a dozen tries but not the point of failure. Here other filament types might work even better, maybe even to the point of competing with a CNCed metal die.
Considering that this was a first attempt without a lot of pre-existing knowledge it went pretty well, and a future video was promised in which improvements will be shown off.
If the PLA is used to make a mold for a plaster pattern for casting zinc alloy dies, many thousands can be made from a single die. The printer sidesteps the WW II wooden pattern making. Such dies would make around 15,000 fuel tanks before they wore out. Which was generally more than they ever made before a new air plane model went into production instead.
Why do I see a pingas? It’s funny.
With things like this, where you could imagine plenty of ways to maks the tool, the helpful part is just seeing examples of what works.
For instance, I wouldn’t have the patience to print anything with solid infill – but knowing that this works, I would be confident to try a hollow PLA part filled with resin or plaster.
People have been doing this for quite a while now. I’ve seen examples of it 2+ years ago, why is it just now a hack? and yes it was submitted back then
It’s an older hack, sir, but it checks out.
https://www.youtube.com/watch?v=CpiP_jN1Pv4
Should anneal the aluminum. I’ve stamped copper and brass, annealed, doesn’t punch thru, but could be die clearances.