Tim's Aluminium Label Maker
by Palingenesis in Workshop > Metalworking
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Tim's Aluminium Label Maker
![Instructable 000.png](/proxy/?url=https://content.instructables.com/FMC/ZMTU/LKL60RWK/FMCZMTULKL60RWK.png&filename=Instructable 000.png)
![Tim's Aluminium Label Maker](/proxy/?url=https://content.instructables.com/FTF/E4PL/LKMLGQ7J/FTFE4PLLKMLGQ7J.jpg&filename=Tim's Aluminium Label Maker)
This Instructable is how I made some one inch high Aluminium labels from Aluminium drink cans.
The process requires a 3D Printer to print the Die used to make the set of alphanumeric characters I designed.
- There is a 3D printed press.
- A set of 3D printed rollers.
- Also a 3D Printed pair of shaped pliers, for crimping the borders.
The end result is a little rough, but I think it give it a classic look.
- I think it gives more of a polished cast aluminium look.
Once the tools have been made there is not much to the Instruction, it may be best understood in the video.
Supplies
![Old Cans.png](/proxy/?url=https://content.instructables.com/F4O/5NVW/LKMLGCRG/F4O5NVWLKMLGCRG.png&filename=Old Cans.png)
![My 3D Printer 1200x1000.png](/proxy/?url=https://content.instructables.com/FA0/3AD9/LKMLGCRD/FA03AD9LKMLGCRD.png&filename=My 3D Printer 1200x1000.png)
![Screws.png](/proxy/?url=https://content.instructables.com/FW7/FQXE/LKMLGCRE/FW7FQXELKMLGCRE.png&filename=Screws.png)
![Bearings.png](/proxy/?url=https://content.instructables.com/FOG/MAI4/LKMLGCRF/FOGMAI4LKMLGCRF.png&filename=Bearings.png)
![Pencil Torch.png](/proxy/?url=https://content.instructables.com/F4Q/M63S/LKMLGCS3/F4QM63SLKMLGCS3.png&filename=Pencil Torch.png)
![Scissors.png](/proxy/?url=https://content.instructables.com/FF7/YTUM/LKMLGCY2/FF7YTUMLKMLGCY2.png&filename=Scissors.png)
![Pan Scrubber.png](/proxy/?url=https://content.instructables.com/FIW/AOZN/LKMLGFLW/FIWAOZNLKMLGFLW.png&filename=Pan Scrubber.png)
As I have mentioned, a 3D printer is required to make the tools.
- A full list of all the required parts are attached.
- My printer has a 0.4mm diameter nozzle.
- To save some time, I have the layer thickness set to 0.3mm.
- Shell thickness is 1.8mm.
- Fill density is 20%.
Being able to hold the tools in a vice is a must.
Several screws are required.
- M3 x 10mm Flat End Self-Tapping screws for fixing the tools together.
- M1.7 x 6mm Flat End Self-Tapping screws for fixing the labels to whatever.
Eight 3x10x4 Roller Bearings are required.
Some old Aluminium Drink Cans.
Small Flame Torch to Anneal the Aluminium.
A Pair of strong Scissors.
Every day items like pencil, ruler and Pan Scrubber.
Downloads
The Press
![Press Brake-Out.png](/proxy/?url=https://content.instructables.com/FYS/8MVI/LKMLGMSQ/FYS8MVILKMLGMSQ.png&filename=Press Brake-Out.png)
![Press Assembled.png](/proxy/?url=https://content.instructables.com/F0P/6CXH/LKMLGMSP/F0P6CXHLKMLGMSP.png&filename=Press Assembled.png)
Hopefully the Brake-Out Sketch shows how the Press goes together.
Printed Parts:
- Base_Body.stl
- Base_Side.stl (Printed as is)
- Base_Side.stl (Printed Mirror Image)
- Roller.stl
- Washer.stl (Four Required)
- Arm.stl
Notes!
There is only an STL for one side, the other side needs to be a Mirror Print.
There are washers on the inside of each bearings.
- I found it easier to place the roller in position, then fit the washer, then the bearing and finally the screw.
- I did the same as a above for the Arm after connecting the two sides.
Screws used.
- Ten M3 x 10mm long flat ended self tapping screws.
Rollers
![Roller Breake-Out.png](/proxy/?url=https://content.instructables.com/FW2/5KP1/LKMLGR3L/FW25KP1LKMLGR3L.png&filename=Roller Breake-Out.png)
![Roller Assembled.png](/proxy/?url=https://content.instructables.com/FA8/8YDY/LKMLGR3M/FA88YDYLKMLGR3M.png&filename=Roller Assembled.png)
Again hopefully you can see how it goes together from the Brake-Out sketch.
Note!
The two screws that the top piece pivots on, should be unscrewed a little, to enable the sides to spring past the screws that hold the lower roller.
Pliers/Crimp
![Pliers Breake-Out.png](/proxy/?url=https://content.instructables.com/F5O/LUKL/LKO0VS6Q/F5OLUKLLKO0VS6Q.png&filename=Pliers Breake-Out.png)
![Pliers Assembled.png](/proxy/?url=https://content.instructables.com/FN2/V2G5/LKO0VS6P/FN2V2G5LKO0VS6P.png&filename=Pliers Assembled.png)
Just one screw holds these together.
These are used to re-shape the top and bottom of the labels.
Aluminium Strips
![Can.png](/proxy/?url=https://content.instructables.com/F4B/CI6G/LKO0WEYK/F4BCI6GLKO0WEYK.png&filename=Can.png)
![Can Open.png](/proxy/?url=https://content.instructables.com/F50/V3R2/LKO0WEYJ/F50V3R2LKO0WEYJ.png&filename=Can Open.png)
The aluminium Strips are cut from Old Drink Cans.
- Cut off the Top and Bottom shaped part of the Can.
- Cut the middle part along its length.
- Flatten the centre piece and and cut into One Inch Strips (25mm)
The Aluminium from Old Drink Cans has been work hardened through the process of making them.
- They need to be annealed to soften the Aluminium.
- If the Aluminium is not soft the Die will not be able to shape the Aluminium.
To Soften the Aluminium it needs heating with a flame torch.
- To anneal Aluminium requires a special heat process, but I do it a simple way and it's good enough for this.
- From the painted side, use the flame torch to heat the Aluminium.
- Don't rush it with a too hotter flame, you will just melt the Aluminium.
- Keep heating it until it turns a golden brown.
- As one area turns golden brown, move along the strip to another area.
- Once it all has turned golden brown your done.
- Let it cool on its own.
You may want to hold the strip with some tool so you don't burn yourself.
Die
![Die E.png](/proxy/?url=https://content.instructables.com/F46/ZKL0/LKO0VVJN/F46ZKL0LKO0VVJN.png&filename=Die E.png)
![Press 3D.png](/proxy/?url=https://content.instructables.com/FZ6/1F1X/LKO0VVJO/FZ61F1XLKO0VVJO.png&filename=Press 3D.png)
![Press From Side.png](/proxy/?url=https://content.instructables.com/FT6/7KZF/LKO0VVJP/FT67KZFLKO0VVJP.png&filename=Press From Side.png)
Die are used to create the characters in the Aluminium Strip.
- The Aluminium Strip is placed between the two parts of the Die.
- Then the Die is placed in the Press to form the Character required.
It is best to hold the Press in a Vice, it will make it easier to use.
Top/Bottom Ridge
![Crimp.png](/proxy/?url=https://content.instructables.com/F59/ROJL/LKO0XO6K/F59ROJLLKO0XO6K.png&filename=Crimp.png)
After the Characters have been formed, use the Pliers to re-form the top and bottom of the label.
Roll/Flatten
![Rolling.png](/proxy/?url=https://content.instructables.com/FZH/3T9S/LKO0XR9Y/FZH3T9SLKO0XR9Y.png&filename=Rolling.png)
At this point the label may be a little twisted/curved.
- Placing it in the rollers and carefully running it back and forth, will reinforce the shape, to make it flat.
Drill and Trim
![Instructable 000.png](/proxy/?url=https://content.instructables.com/F3M/00DS/LKO0XVUJ/F3M00DSLKO0XVUJ.png&filename=Instructable 000.png)
Next step is to drill the mounting holes and trim the outer edges.
- Once you have it on a flat surface, you can use a rough cleaning pad to enhance the characters by removing the staining from the annealing process from the top surface.