Prototype to Production, September 20 – 22, 2024

September 20 – 22, 2024
Wesleyan Potters,
Middletown, Connecticut

SKU: September 20 - 22, 2024 Category:


Register at: Wesleyan Potters

Take your designs from flat to three dimensional with this in-depth workshop from Jayne Redman. Learn the innovative design and assembly concepts that Jayne has developed over 40 plus years of metalsmithing. Jayne will teach you the principles behind centrally radiating forms, properly nested forms, spacing for slotted forms, faux hinge assembly, and tab construction. She will show you how to use your computer as a design tool and how to duplicate the same steps manually. Learn how to make blanking (pancake) dies to quickly cut out the shapes you develop in class and get lost in the process of experimenting with forming and assembly. Speed up your production or incorporate identical shapes in one-of-a-kind pieces.

Techniques taught:

• Developing flat patterns used for three dimensional forms
• Prototyping with heavy aluminum foil
• Using your computer as a design tool or creating the same design manually.
• Layout for a correctly designed blanking die
• How to correctly use a saw frame and choosing saw blades for sawing tool steel
• How to determine rotational angle of your bench pin relative to thickness of tool steel and saw blade
• How to saw a blanking die out of tool steel
• How to use a hydraulic press or bench vise to blank out metal with blanking dies
• Tips and tricks using flex shaft accessories
• How to make your own forming tools

Additional information

Tools and Materials

Bring your metalsmithing toolbox including the following items:
5–6" deep Jeweler's Saw Frame
Center Punch
1.5mm ball bur
Bur life
#58 or #60 HSS Twist Drill bits (Rio Grande #349419)
Joyce Chen Shears or similar
Flat or Half-round hand file, #0 or #1 cut
Copper and/or brass to test dies, 22ga
Exacto knife
Dust mask
Safety Glasses
Laptop or Tablet with Adobe Photoshop installed
Eye Magnification
Silver or gold sheet: 23 gauge or thinner to use with blanking dies 1/32” thick – 19 gauge or thinner to use with blanking dies 3/64” thick; (sheet stock can be rolled down to appropriate gauge)
Delrin/Acetal Round Rod Assortment 1/4" to 1", (from Online Metals or PlastiCare)
Wolf Wax Trimmer (Rio Grande #700333) used with a cylinder bur to create 90 degree walls on your silhouette die for mirror image pieces
Wolf Wax High Speed Cylinder Wax Burs: 25mm x 6.3mm, 25mm x 4.7mm, 25mm x 3.3mm (Rio Grande #345013, 345012, 345011; or Otto Frei #119.850, 119.851, 119.852)
eye magnification
additional saw blades in 2/0 or 3/0 (you will receive some in your kit, but you may want more)