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.

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.

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.

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.

Just one screw holds these together.

These are used to re-shape the top and bottom of the labels.

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 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.

After the Characters have been formed, use the Pliers to re-form the top and bottom of the label.

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.

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.