Embossing

Metal embossing is a process for production of either raised or sunken designs on the sheet metal. This process can be carried out easily by matching a male and female dies, and their passage between rolls in accordance to the pattern desired. This process can be combined with foil stamping in order to create a shiny surface of embossing with 3D effect.

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It is a forming process that does not change the metal sheet thickness when rolled between rolls for a desired pattern. This process can also be used either in papers and other materials.

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Features:
It has an ability to form ductile metals. These are mostly used in high production runs, and it has an ability to maintain same thickness before and after embossing. The process had an ability to produce unlimited patterns depending on the roll dies. The reproductions of product can be possible with no variations. To maintain the top as well as bottom registration the rollers are geared together where they are located in the embossing stand. The strip width, material thickness, pattern depth, tensile strength along with hardness, forms a basis for the width and diameter of the rolls. In most of the cases the upper blocks are stationary and the lower blocks are movable. Tonnage capacity is referred as the pressure with which the bottom roll is raised.

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Many embossing machines are costumed manufactured. Therefore there are no any sort of industrial standards. The main purpose of using embossing metals in industry are their functionality and aesthetic nature. Appliance panels, elevators panels, building products, automotive trim, garage door panel, metal made office furniture etc. that are included in aesthetic applications. Functional applications are enhanced in their performance characteristics They include metal product ability for an effective disperse of the liquid, reduction of friction and static, metal panel stiffness and rigidity increment, metal surface area increment for acoustic as well as heat transfer application that improvises traction.

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Embossing process can produce variety of patterns. Stucco, leather grain, wood grain, rough sawn cedar etc. are the most common types of patterns.

Common materials:

Most common materials used in the process of metal embossing is :

• Aluminum (Al alloys)
• Aluminium (T1/T2)
• Brass
• Cold rolled steel
• Copper
• Galvanized steel
• High strength, low alloy steel
• Hot rolled steel
• Steel (All alloys)
• Zinc

Types of metal embossing dies:
There are three varieties of metal that are used as the dies of embossing. The selection of dies among them depends on the shape of the image, texture that is to be created along with the run that is selected as a metal.
Magnesium dies: These dies are used for the easy embossing processes in short runs. These designs are uncomplicated and are very large. This metal offers the special hand tooling facility
Brass dies: Brass dies are most popular and common among the embossing dies. These are very much flexible and these give an embosser leeway in order to create sculptured images, fine lines, stamping along with embossing of combo foil type. These are best suited for the images that require extensive hand tool. Brass dies can be made directly from machines or by semi-photo graphic process. The photograph gets transferred onto the die that is used as guide for the purpose of drawing.

Copper dies: These dies are used between the magnesium and brass dies. These dies do not allow the hand tooling.

Process:

• This process is generally accomplished by a combination of heat and pressure on a sheet metal, that depends on the type of required embossing.
• Theoretically anyone of these procedures decreases metal thickness in its composition.
• Metal sheet is drawn between the male and female roller dies that produces required design on the metal sheet. The metal sheet pattern depends on the usage of specific type of roller dies.

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The pressure and the heat combination used will iron the metal sheet while raising the image level.
• The impressing refers to the image lowering into the surface of the material in distinction to the image that is raised out from the metal surface of the material.
• Embossing machines are generally sized up to 2” of the strip clearance on every side of the roll that is engraved and embossed.

Precautions:
• It is required to keep the design bold and uncluttered.
• Tiny cross lines and the fine details are to be minimized.
• Sans serif fonts and space in them are to be preferred while using the letters in order to have enough space in between the letters; this allows the easy effect of embossing on the metal sheet.
• To compensate the added dimensions the art size is to be increased slightly.
• Color codes are preferred to use in multi-level embossing in various levels.
• The image area should be 0.25 inch away from the over sized sheet edge in order to avoid the wrinkling and puckering.
• After the completion of the process the finished work is to be kept with 0.5 margins

 

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Embossing is generally made of paper objects like cards, letter writing papers and envelops, paper gift bags and other kinds of stationary. These small embossing works on these objects will increase their commercial value. These are used great with the method of personalizing gifts as leather wallets or diary. These embossing processes are use in publishing braille symbols and books for the blind.

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