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| The Template |
This sneaker template is a challenging shape to make, because it involves a lot of curvatures. This object is very different from the handheld vacuum, a handheld vacuum is a man-made object with a straightforward streamline. However, a sneaker is more of an organic shape, as it is made to fit the human foot. So, in order to fabricate an accurate sneaker skin, we have to be able to create so nice and smooth curvatures, which involves some new and more challenging techniques. Enjoy the tutorial!
First, use a string to measure the length and width of the template. It is a good idea to have a mate helping you to mark the measurements, as accurate measurements allow you to cut an accurate metal sheet, hence you don't have to waste additional time to recut an inaccurate skin later.
After the measurement, use a dark and thick pen to mark the shape on the metal sheet. You don't have to worry about the marks, they will fade out gradually during your metal shaping process, and you can sand the marks away too.
When cutting the metal sheet. Make sure you get each single cut as long as possible, as short cuts will cause uneven cuts. Watch the video to see how my hands move.
Now we are ready to shape the metal skin.
Part 1: Size Measurement And Metal Sheet Cutting
First, use a string to measure the length and width of the template. It is a good idea to have a mate helping you to mark the measurements, as accurate measurements allow you to cut an accurate metal sheet, hence you don't have to waste additional time to recut an inaccurate skin later.
After the measurement, use a dark and thick pen to mark the shape on the metal sheet. You don't have to worry about the marks, they will fade out gradually during your metal shaping process, and you can sand the marks away too.
When cutting the metal sheet. Make sure you get each single cut as long as possible, as short cuts will cause uneven cuts. Watch the video to see how my hands move.
Now we are ready to shape the metal skin.
Part 2: Shaping the Metal Sheet
Draw the fold line on the skin and we will stretch and fold the skin along this line.
Use the sharp edge of the mallet to hit along the fold line. Be patient and keep hammering along the line the stretch the skin, try to hit as accurately on the line as you can.
Use the sharp edge of the mallet to hit along the fold line. Be patient and keep hammering along the line the stretch the skin, try to hit as accurately on the line as you can.
Use the round edge to stretch the bottom part of the skin in order to create the natural curve shape of the sneaker.
Use the shrinker to help yourself getting a more obvious fold line. However, beware NOT to over rely on it, as the shrinker will leave some scratch marks on your metal skin, which are extremely hard to get rid of.
This does not fit quite well.
Notice the big gap between the skin and the template. I am going to mark the bulged out part of the skin and push it in to fit the template.
I am choosing a diagonal shaped timber to hammer on, and notice i used a flat mallet instead of a round one. Be patient as it takes time to push in the bulged out part.
Watch the video to see my hammering motion.
The gap is much smaller now.
Now the diagonal edges are all gone and it really resembles organic the shape of a sneaker.
See how closely the skin adheres to the template.
I hope you enjoy the tutorial. Have fun making lots of beautiful skins!
This does not fit quite well.
Notice the big gap between the skin and the template. I am going to mark the bulged out part of the skin and push it in to fit the template.
I am choosing a diagonal shaped timber to hammer on, and notice i used a flat mallet instead of a round one. Be patient as it takes time to push in the bulged out part.
The gap is much smaller now.
Part 3: Smoothening and Curving the Metal Skin
Now the skin starts to fit. However, it is very diagonal and does not resemble the organic shape of a sneaker. In this part, I am going to smoothen the diagonal part of the skin to make it fits nicely to the template.
Position this curved steel dolly as shown in the image above. Place the diagonal edge of the skin on it and start to smoothen it, this takes time so be patient.
Make use of this dolly to smoothen the head of the sneaker skin.
Now the diagonal edges are all gone and it really resembles organic the shape of a sneaker.
See how closely the skin adheres to the template.
Final Skin
I hope you enjoy the tutorial. Have fun making lots of beautiful skins!
Reflection
I chose this object from another student because it has an organic shape that contrasts with the diagonal and streamlined shape of my own found object. As an future architects, we will have chance to design buildings in diagonals and curves, so I think the two objects help me to explore different forms and shapes.
I am quite happy with the final skin. However, I think I might do better if I made use of more equipments in the fab lab. For example, I have not got a chance to use the English Wheel to smoothen the metal skin, so the final product is not as smooth as I expect.
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