Optional Lesson C

This session aims to ignite students’ curiosity about metalwork, drawing intriguing comparisons between sheet metal crafting and paper crafting. It’s a fun, hands-on way for students to learn and apply their creativity.

1. Assorted sheet metal (thin and flexible)
2. Safety goggles
3. Metal cutting tools (e.g., tin snips)
4. Metal shaping tools (e.g., hammers and mallets)
5. Sandpaper or files
6. Markers or paint for decoration
7. Optional: Examples of sheet metal crafts or objects

Kick off the session with an exciting revelation: metal, like paper, can be cut, folded, and shaped into various forms. Explain the session’s objective and build anticipation for the activities ahead.

Showcase the magic of metalwork through a live demonstration. Show students how metal can be cut with tin snips and shaped with hammers and mallets. Discuss the various techniques involved in metalwork, such as cutting, bending, folding, and joining. Emphasize safety precautions and demonstrate the correct use of safety goggles and tools.

Stir students’ imagination by drawing parallels between sheet metal work and paper craft. Discuss how the techniques used in paper crafting can be similarly applied to metalwork. 

Encourage students to think creatively about how they can transfer their paper craft skills to metalwork.

Here are some techniques in paper craft and students can practice to understand metal craft –

• Cutting: Just as you would use scissors to cut paper into different shapes and sizes, you can use tin snips or other metal cutting tools to cut sheet metal. The process involves marking the desired shape on the metal and then carefully cutting along the marked lines.
• Folding: Folding is a common technique in both paper and metal crafts. In paper crafts, you might fold paper to create origami or other 3D structures. Similarly, in metal crafts, you can fold sheet metal to create different shapes and forms. This is usually done by marking a line where the fold is desired and then bending the metal along this line using a tool or your hands (with protective gloves).
• Embossing: In paper crafts, embossing is a technique used to create raised designs or relief images on paper. This is done by pressing a stencil or die into the paper. Similarly, in metal crafts, you can emboss sheet metal to create textured designs. This is usually done by placing the metal on a soft surface like a rubber mat and then using a stylus or other pointed tool to press the design into the metal.
• Punching: Punching is another technique common to both paper and metal crafts. In paper crafts, hole punches are used to create holes of various shapes and sizes in the paper. In metal crafts, you can use a metal punch to create holes in sheet metal. This is done by placing the metal on a hard surface and then striking the punch with a hammer.
• Joining: In both paper and metal crafts, there are various techniques for joining pieces together. In paper crafts, this might involve using glue, tape, or staples. In metal crafts, you can join pieces of sheet metal together using various methods such as riveting, soldering, or welding.
• Decorating: Both paper and metal crafts can be decorated in a variety of ways. In paper crafts, you might use markers, paint, or stickers to decorate your creations. In metal crafts, you can use paint or other types of metal finishes to decorate your creations. You can also use techniques like engraving to create designs on the surface of the metal.

Now, it’s time for students to get their hands dirty. Provide each student with a small piece of sheet metal and basic metal cutting and shaping tools along with chart paper. Guide them to practice cutting and shaping the metal using the demonstrated techniques. Encourage creativity and experimentation, allowing students to explore the endless possibilities of metalwork.

This activity is divided into two parts: a paper crafting exercise followed by a similar exercise with sheet metal.

Part 1: Paper Crafting

Provide each student with a piece of chart paper and basic crafting tools like scissors, glue, and markers. Instruct them to plan and create a simple object or design using the paper. This could be a 3D structure like a cube or pyramid, a folded design like an origami animal, or a cut-out shape like a star or heart. Encourage them to be creative and think about how the techniques they’re using with paper (cutting, folding, joining, etc.) could be applied to metal. Encourage them to stick to creating simple geometries like Cube, Rectangular prism etc.

Part 2: Metal Crafting

Once the students have completed their paper crafts, provide each student with a small piece of sheet metal and basic metal cutting and shaping tools. Instruct them to recreate their paper design with the sheet metal. They should use the techniques demonstrated earlier to cut, fold, and shape the metal. Remind them to wear safety goggles and gloves while working with the metal.

Engage students in a lively discussion about their metalwork experience. Encourage them to share their observations, challenges, and the parallels they noticed with paper craft. Encourage them in writing about the differences in Papercraft and sheet metal work. Facilitate a reflection on how their newfound knowledge of working with metal can enhance their maker projects and expand their creative possibilities. 

Here are some key differences:

• Material Properties: Paper is lightweight, flexible, and easy to cut and fold, making it ideal for a wide range of crafts. Sheet metal, on the other hand, is heavier and more rigid. While it can also be cut and folded, it requires more effort and specialized tools.
• Safety: Papercraft is generally safe and suitable for all ages. Sheet metal work, however, requires more caution due to the sharp edges of cut metal and the tools used. Safety equipment such as gloves and safety goggles are necessary when working with metal.
• Durability: Crafts made from paper are typically more fragile and temporary, while those made from metal are more durable and long-lasting. Metal crafts can also withstand outdoor conditions, while paper crafts cannot.
• Techniques: Some techniques are unique to each material. For example, in paper craft, you can create textures or patterns by simply drawing or printing on paper. In metalwork, creating textures or patterns often involves more complex techniques like embossing or engraving.
• Joining Methods: In paper craft, pieces can be easily joined together with glue, tape, or staples. In metalwork, joining pieces together can involve more complex methods such as welding, soldering, or riveting.
• Finishing: Paper crafts can be easily colored and decorated using paints, markers, or stickers. Metal crafts, on the other hand, may require special paints or finishes, and can also be polished to a shine

Wrap up the session by summarizing the key points covered, emphasizing the parallels between sheet metal work and paper craft. Highlight the potential of working with metal in creating unique and durable prototypes for maker projects. Encourage students to continue exploring and experimenting with metal in their designs, incorporating their understanding of paper craft techniques.

To further enhance the learning experience, teachers can use the following video resources:

1. The Basics Of Sheet Metal Fab: A brief introduction to sheet metal fabrication.
2. SolidWorks Sheet Metal Basics: A tutorial on basic features like Base Flange, Edge Flange, Sketched bend, and Extruded Cut in Solidworks sheet.
3. How To Weld Sheet Metal With Flux Core Wire For Beginners | Flux Core Welding Tips And Tricks: Tips and tricks for welding the thin gauge sheet metal.
4. Metal Shaping with ONLY Hand Tools STEP BY STEP!!! How To Make Compound Curves: A demonstration of how to shape metal using only hand tools.
5. Let’s Build A Simple Sheet Metal Tool Tray: A tutorial on fabricating a simple one-piece tool tray from scrap metal.