This project explores a way to use your Emblaser to create an embossing tool.
I will be embossing aluminium from a can, but these techniques can be used on a variety of materials.
Project Files
Materials:
- Aluminium can
- 600 gsm card
Other Items Needed:
- Paper glue
The Build
I started the project by harvesting the aluminium from some empty cans.
![](https://darklylabs.com/wp-content/uploads/2019/10/build01-3-1024x829.jpg)
I very carefully cut the ends off the cans. These parts are sharp, so I took my time.
![](https://darklylabs.com/wp-content/uploads/2019/10/build01a-1024x672.jpg)
![](https://darklylabs.com/wp-content/uploads/2019/10/build02-3-1024x779.jpg)
I then cut the remaining cylinder lengthwise to end up with a rectangular sheet. To help flatten the sheet out and remove some of its curvature, I ran it along the edge of the desk.
![](https://darklylabs.com/wp-content/uploads/2019/10/build03-4-1024x786.jpg)
For this project, I chose the famous ‘Don’t Panic’ sign from The Hitchhiker’s Guide to the Galaxy. I particularly liked this design because it would allow me to add 2 levels of embossing from the edge that runs along the outside of the lettering.
In LightBurn, I used the ‘Trace’ function to create outlines from the image.
![](https://darklylabs.com/wp-content/uploads/2019/10/LB01-3-1024x583.png)
![](https://darklylabs.com/wp-content/uploads/2019/10/LB02-1.png)
I separated the inner and outer lettering into two parts. These will form the positive and negative parts of the embossing tool.
![](https://darklylabs.com/wp-content/uploads/2019/10/LB03-1-1024x643.png)
The Emblaser made quick work of cutting these pieces out. Along with the lettering, I also cut out two rectangles from card which will form the backings for the embossing tool.
![](https://darklylabs.com/wp-content/uploads/2019/10/laser01-2-1024x836.jpg)
![](https://darklylabs.com/wp-content/uploads/2019/10/build04-3-1024x677.jpg)
By using the existing pieces as guides, the assembly proved very easy. I first joined the two negative parts of the tool.
![](https://darklylabs.com/wp-content/uploads/2019/10/build05-3-1024x768.jpg)
I then used this negative side to help position the positive side letters.
![](https://darklylabs.com/wp-content/uploads/2019/10/build06-3-1024x789.jpg)
![](https://darklylabs.com/wp-content/uploads/2019/10/build05a-1024x768.jpg)
Finally, the backings were added to the tool sides.
![](https://darklylabs.com/wp-content/uploads/2019/10/build07-3-1024x624.jpg)
It will be important for both of these parts to perfectly align with each other when the tool is closed. To make sure this happens, I taped one edge together.
![](https://darklylabs.com/wp-content/uploads/2019/10/build07a-1024x766.jpg)
![](https://darklylabs.com/wp-content/uploads/2019/10/build08-2-1024x507.jpg)
There are many techniques for pressing the tool over the aluminium. A rolling pin can be used as well as an embossing press. In our case we used a workshop press to apply pressure to the tool.
![](https://darklylabs.com/wp-content/uploads/2019/10/build09-2-1024x768.jpg)
The final results were very promising. I did notice some wrinkling around the lettering which was most likely caused because I was trying to stretch the aluminium a bit too far. There was also a little tearing on some of the inner letters.
In the future I will experiment with allowing a little more gap between the positive and negative sides of the tool which should allow the material to conform a little better.
![](https://darklylabs.com/wp-content/uploads/2019/10/final02-2-1024x768.jpg)
![](https://darklylabs.com/wp-content/uploads/2019/10/final01-3-1024x768.jpg)