BEIL0014 Digital Making -- Project 3: The Tray

This week's task is focused on a tray: an open box-shaped form which has radiused corners. The main technique we were using is called Hammer Forming.

Material Preparation: Aluminum Sheet, Scrap Timber, Timber Template, Steel Rule.







This time I paired with a friend to make trays together. We decided to make both trays with an aluminum sheet of 200mmx110mm, the setback is 10mm ( it is also the depth of the tray), inner radius is 15mm (by using 30mm circle timber template), so the outer radius should be 25mm (by using 50mm circle).

Step 1: Make the Hammer Forming Buck with scrap timber. Mark out the timber with the same size of the tray. Form the radius of the edge with a Disc Sander.








Step 2: Mark out the aluminum sheet with the decided dimensions. Cut the piece with Hand Lever Shear.









Step 3: Clamp the aluminum piece with 2 Hammer Forming Bucks, tight it up with Bench Vise. Using planishing hammer slowly hammer down the edges of the piece.









Step 4: While hammering, the corner of the tray is quite difficult to get even & smooth. I used a rounded surface like a dolly to smoothen the corner.








Step 5: Repeat Step 3 to form the shape and smoothen the corner.









 The result after hammering. the tray fits perfectly with hammer forming buck.








Step 6: After hammering, especially the corner of aluminum tray expanded on open edges. I decided to use File to polish the edges to make them even.










Finish Product

Join with another tray to see the match.