About

Cost: $ $ $ $ $

Difficulty: • • • • •

Time: 2h00

Adding texture to printed aluminum lends a completely new dimension to your design.
Adding texture to printed aluminum lends a completely new dimension to your design. Layering colors and patterns with texture creates interesting depth and offers infinite possibilities of combinations.

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Step 1
To create the first layer of color, use a paintbrush to cover the stamp with pale aqua/green ink.
Step 2
Firmly press the inked stamp onto the aluminum, and carefully lift it off to prevent smudging. Continue this process to cover the aluminum as desired.
Step 3
Using either a new stamp or the same one (cleaned with acetone), repeat steps 1 and 2 with turquoise ink. Leave to dry.
Step 4
Overdye the stamped aluminum sheet in the brown water-based dye. The stamped area will remain the original color. Rinse and steam the stamped and dyed metal.
Step 5
When the steaming process is complete, remove the ink from the aluminum with thinner and thoroughly dry the metal.
Step 6
Cut the mesh to size and place it on the aluminum sheet.
Tip: If you’re concerned about the mesh moving when it’s rolled through the mill, cut a piece of paper the same size as the aluminum sheet and use double-sided tape to secure the mesh to the paper.
To check that the rollers are set to the right height for a successful print, make a test run with a ?piece of scrap aluminum and a small section of mesh. When you’re happy with the results, you’re ready to proceed.
Step 7
Carefully align the mesh and the edge of the aluminum with the rollers. Steadily turn the arm on the mill until the sheet comes through the other side. Remove the squashed mesh.
Step 8
Using a fine or medium file, bevel the edges of the aluminum to a smooth finish. File each corner into an even curve. Finish all the metal edges and corners with an emery paper until smooth.
Step 9
Place the mandrel in a vise horizontally. Using a rawhide mallet, start to bend each end of the aluminum (photo A). Work steadily to prevent creating folds.
Step 10
Continue hammering until you achieve a smooth curve in a slight oval formation with a gap of approximately 1 to 1½ inches (2.5 to 3.8 cm) as shown in photo B.
Step 11
Use pumice or a kitchen scrub pad and liquid dish soap to clean off any marks left by the mallet on the cuff.