My wife wants to make some flowers like these for fun. I have a low rider, 3d printer, and lots of wood working equipment. I was thinking I could cut the thin metal out and then use some kind of mold either made out of wood or 3d printed and put in in a hydraulic press it to make the shape. I’m a solidworks user but modeling organic shapes isn’t something I’m very good at. Does anyone have good suggestions on how to make flowers like these?
I don’t know how Solidworks operates, but in Onshape I would make one leaf and then reproduce it in a circular pattern.
I’d consider the leaf to be flat and extrude the basic shape to the thickness of the metal. I think I would bend the form in it by hand after pressing the veins - make each of them using a simple loft operation.
After that I’d extrude a solid object enclosing it, then use a Boolean subtraction to create the moulds.
Good luck!
I’d probably just model one leaf and make a single forming die I’d use individually on each petal. Or maybe 2-3 variations. Not sure some of those could be done in one stamping operation anyway the way some of the leafs overlap.
If I was trying to model it I’d probably try more of an artistic mesh modeling package than a CAD package - something more like Blender or Zbrush. Maybe Meshmixer…though it usually just frustrates me 
2 Likes
I do pretty well designing things in CAD, but I struggle with any kind of sculpting app. One thing I’ve tried is combining the two. I start roughing out the design in CAD then take the mesh to a sculpting program to add organic details. For adding organic details, I’ve used MeshMixer (free) and ZBrush Core (paid).
I don’t know Solidworks, but in Fusion 360, it would be relatively easy to rough out a leaf. Both lofts and 3D projections would allow me to model the transitions/terrain of the leaf. I could then cut out the leaf shape from the terrain. Next, I’d output the leaf as a mesh and use ZBrush Core to add any dimples or waves. Note I only need to create one surface, not a double-sided leaf. I can always take the leaf mesh back into Fusion 360 and subtract that mesh to create the mesh for the other side.
ZBrush Core also allows the use of grayscale height maps, and there is a variety of organic height maps that can be used to add organic details to things. You could even start with an evenly lit photograph of a leaf and use the tone gradations to build a height map.
Note my mixing of Fusion 360 and ZBrush Core came from watching this YouTube video.
1 Like
I have seen plastic parts do forms for a press. The points will be very high pressure. So if you wanted those ridges, you may need a multi step press form.
Wood or aluminum is probably better.
2 Likes
The first photo provided looks to me as though the metal petals are simple profiles which are then either rolled (on the left) or a single bend added down the center (either of which would add rigidity). The visible veining patterning on the right seems to come from a surface treatment (brushed finish, angle grinder and flap disk?) which might be easier to accomplish before adding the bend.
The second looks more die-formed to get the ridges on the petals. My guess is that they use a die to press the ridges, then another to cut to shape. If attempting to press these myself from sheet material, I’d try making a die with raised wire to form the ridges, maybe set in a slot routed to the shape desired. I’d have a hard time achieving the needed pressure in my shop, but I don’t have access to a hydraulic press or roller.
2 Likes