Learning Sheet Metal Forming

Using a torch, anneal (heat) metal until it turns a rich cherry-red color.

You can form sheet metal to size by hammering it, bending it, or molding it. Any of these options is made easier if you anneal the metal to soften it before attempting to form it.

Things You'll Need

• Torch and equipment
• Jewelry saw, metal snips or bench shear
• Felt-tipped marker
• Hammer(s) or mallet(s)
• Forming tool(s)

Instructions

1. Cut the piece of sheet metal you want to form to size using a jewelry saw, metal snips, or bench shear.

2. Anneal the sheet metal with your torch. Annealing is the process of heating it so that it becomes soft and malleable. Heat the metal until it turns a rich cherry red color.

3. Mark the sheet metal where you want to form it, using a felt-tipped marker.

4. Gather the tools you need to form the metal. In almost all cases you will need a hammer and some other type of specialized forming tool.

5. Select the hammer you need to use. Specialized hammers help move and finish metal in different ways. For example, a bordering hammer helps thicken the edges of metal. A planishing hammer helps hammer out tool marks on metal and makes the metal shiny. A ball-peen hammer is a good general-purpose hammer for sheet metal forming.

6. Select the tool you need to form the metal. For example, you can use a mandrel to create a ring or bracelet. A vise is used to bend sheet metal and for fold forming. A doming block will dome metal. A swage block is used to shape sheet metal into a tube. Stakes are used to form sheet metal into a variety of shapes and angles.

7. Place the annealed metal in position on the forming tool and use your hammer to strike the sheet metal into the form you want. For example, to dome sheet metal, place the cut sheet metal into a doming block and use a hammer to hit a punch that corresponds with the depression in the doming block. To bend sheet metal, place it into a vise lined with leather or copper to prevent marring, then tighten the vise and bend the sheet metal over it with a hammer.

8. Stop your work to anneal the sheet metal from time to time as you form. The metal will become work-hardened as you go along. Anneal the metal to make it easier to shape and to prevent the metal from cracking.

9. Repeat the forming process as needed, substituting hammers and forming tools as you work until the sheet metal is formed into the shape you require for your project.

Tips & Warnings

• Take fire safety precautions when using a torch.

• Wear eye protection when cutting sheet metal.

References

• "Sheet Metal Handbook"; Ron Fournier, Sue Fournier; 1989
• "Technology of Metal Forming Processes"; Surender Kumar; 2008
• "Handbook of Metalforming Processes"; Henry E. Theis; 1999
• "Mechanics of Sheet Metal Forming"; Donald P. Koistinen, Neng-Ming Wang; 1978

Resources

• "Living Materials: A Sculptor's Handbook"; Oliver Andrews; 1988
• "Form Emphasis for Metalsmiths"; Heikki Seppä, 1978
• "Metalsmithing;" Robert Ebendorf, Michael Jerry, and Thomas Markusen; 1973
• "Jewelry: Fundamentals of Metalsmithing"; Tim McCreight; 1997
• "Complete Metalsmith: Professional Edition"; Tim McCreight; 2005