Instructables

Arduino-controlled, Aluminum Archangel Costume Wings

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Step 3: Cutting the wings

I first traced out the paper templates onto the aluminum sheets. I carefully positioned the paper over the sheets I had to make sure I got the most out of the 4 pieces of Aluminum I had. The secondary wings and the inner panels of the main wings were one solid piece but the large outer main wing panel had to be made from two pieces.

Use the dremel with the fiber reinforced cutting wheels to carefully cut along the patterns on the aluminum. There is a lot of cutting to do, so use safety glasses and earplugs to reduce the wear and tear on your eyes and ears.

Once the wings are cut, wrap the sandpaper around the sanding sponge and go along the edges of the aluminum to remove any burr and make it nice and dull. The wings will have a pretty wide wingspan so you could hurt a lot of people if the edges are sharp.
 
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