Question on Pressed Metal Mesh Grille fabrication

[Blu]

When creating the Male and Female dies - how much gap needs to be allocated between the two pieces?

Is there a ratio / rule of thumb based on the metal mesh thickness and the thickness of the dies themselves?

Example:

• 1/16" metal mesh
• 1/2" wood used for dies

How much gap needs to be allowed and how do you calculate?

T.I.A.
Charles

 

[1low84s10]

Mark from Car Audio Fabrication (https://www.caraudiojunkies.com/member.php?173-caraudiofab) has a video on this very subject. His YouTube channel is here: https://www.youtube.com/user/CarAudioFabrication. Lots of information on system fab and component selection.

Here is the direct link to fabbing mesh grilles: https://www.youtube.com/watch?v=AbpYA6ZkVEQ

 

[BigAl205]

I haven't personally tried it, but I've thought about ways I would do it. My thinking is the gap should be 1.25 to 1.5 times the thickness of the stock being formed

 

[Blu]

I haven't personally tried it, but I've thought about ways I would do it. My thinking is the gap should be 1.25 to 1.5 times the thickness of the stock being formed

Yeah, I haven't done it either but we seem to be thinking along similar lines.

I guesstimated a 3/16" gap based on a 1/16" allowance for each side of the male die plus another 1/16" for good measure.

Is this similar to what you were getting at @BigAl205 ?

I might just have to try it and find out for myself, but I have limited amount of the metal mesh on hand and really don't want to waste material if I can avoid it.

 

[BigAl205]

I guess it depends on the shape of your mold and buck. If the edges were a slight angle, say 45 degrees or less, you could probably get away with just the 1/16" material thickness gap. As the sides become more vertical, you'd need more gap to allow compression/distortion of the material and to allow release after done.