Silhouette Cutting and Foiling, Thermal Lamination

Remember Bigweld saying, "see a need fill a need"?

Thermal foiling and glittering is very trendy right now and often requires a laser printer, laser printed pre-made die-cuts, lamination machine, glue, toner paint and so on.

Let me show you another way, using thermal lamination material. Sometimes people use Sticker material, cutting out their shapes and then using the adhesive side to adhere foil, but lets face it sometimes you need something more durable.

Lamination sheets, rolls and pouches come any varying thickness. The material is plastic with heat activated adhesive and once heated is clear, unless otherwise noted. Multiple layers can be heat formed to make unique shapes.

Sure you can laminate objects between the 2 sheets and cut out shapes, but it becomes a very hard plastic, almost impossible at times to cut and then both sides tend to be shinny.

Before heat is applied it is soft ,not sticky and easily cut.

Perfect time for a digital die-cutter, then when paired with other great materials you get some really superb looking products.

We will create beautiful foiled shapes for this Vogue Necklace and crown, and show examples of Steampunk card, and tidbits.

Collage : made with App PhotoCollage

Step 1: Gather the Stuff!

Lamination pouches,sheets or rolled material. ( 3- mil.,5- mil. 7- mil.,10- mil.) Lamination Depot is a great supplier.

House hold Iron ( or lamination machine)

Teflon or silicone mat

Reactive thermal foil ( called Reactive foil,Toner Reactive, hot foil stamping ) Available at most craft stores.

Glitter

Scissors

Heat gun ( helps with forming )

Glue stick or dbl sided tape

Digital die-cutter, regular die-cutter,scissors or craft punches

Heat safe work area ( i use a piece of tempered glass and a cutting mat)

Project ideas and sizes ( This will determine what material you will want to use)

Patterns purchased from the Silhouette design store.

Step 2: The Design and Lamination Prep.

Like I said before the lamination material comes in many sizes and thickness. You need to keep in mind that if you will be using pouches you will get two pieces from each one. There are different process styles involved that yield different results. Play around with your material.

The amount of pressure you apply can change the look. The Lamination machine keeps pressure very even and the heat is maintained, some basic thermal Laminators only heat to certain temp. A Clothing iron has a temp.setting and you can apply pressure as needed. Some thicker materials only work with higher heat.

Process styles:

Completely encapsulated: This is a process were you foil or glitter a die- cut and then create 2 larger, outer shapes (called off sets) that are a mirror of each other, then seal the edges. This is similar to the existing process.

Clean faced: Just the surface is foiled or glittered and heat applied (used for the necklace)

Backed: A duplicate shape is created and one is placed on top of the other, then the Foil or other material is placed on the glue side of that shape, and heated. (Used for the crown)

Cover faced: Mirror the shape when cutting, add foil or Glitter, and place other shape on top and heat.

Test your machine with all materials. I am not responsible for what and how you use your cameo, ETC.

(Cut settings for my Silhouette Cameo)

3- mil (cardstock plain) blade - 3 & no dbl.cut

5- mil (cardstock plain) blade - 3 & no dbl.cut

7- mil (fabric) blade -5 & no dbl.cut

10- mil pouch (coverstock heavy) blade 7 & dbl. Cut

10- mil roll (coverstock heavy) blade 7 & no dbl.cut the plastic is different in my rolled material than the pouch. I could have used 3- mil pouches for my leaves, but this 10- mil is stronger, yet soft.

Step 3: The Leafy Necklace

We start with 10- mil. rolled laminate. (Only used it because, it was salvaged from printing company)

I found a pretty cluster of leaves pattern from the Silhouette store and after taking measurements of my mannequin; the calculations were transferred to the program. The laminate was cut 12" x 12" to fit my cutting mat.

In the setup, the blade was set to 7 and cover stock heavy was selected as material and no dbl.cut.

I took an old gold chain, placed it around the neck of the mannequin and adjusted it for the right length, 5 clusters of leaves would be just enough to fill the area. The Leaves are 6" long and 6" wide ,the soft lamination lets them curl like we want.

We will be using the clean-faced style. The leaves need to look like they have movement and are delicate in nature.

After setting up the design and cutting them out, they are carefully removed from the mat. The clothing iron temperature is set between wool and cotton (adjust the temp.for your particular material)

Please Please use caution, so no one gets burned,nothing gets melted that wasn't intended to or start a fire. Have your area prepared for a hot iron. (I use lamination machine, clothes iron, mini iron and hair irons to get lots of variations) BE SMART

Now when you start to foil make sure to use cover sheets they will help balance the heat and keep from sticking to the iron.

Both copy paper or Teflon sheets are used as the cover sheet. The Teflon sheet will keep everything from sticking.

Here you see copy paper, there is no glue area going to touch the paper, the foil sheet covers it.

apply heat in a smooth waving fashion; it was previously tested on scrap material to check temp and foil bonding.

Let cool and peel of foil, if some areas didn't cover you can apply more foil. (Just remember prolonged heat changes the look of the foil)

Step 4: Fashion Week Here We Come!

Well OK maybe not fashion week, but can't stop a girl from trying.

With the necklace in place and leaves all foiled. We simply add a little glue to the end of each leaf cluster, fold over, stick and let dry. Now if you have some of that UV curing glue yippee. (Tip: sand the shiny side whenever you are going to adhere something to it, makes a better bond) Double stick tape was used on this necklace.

Another great thing to mention is that, say you don't like flat looking stuff, no worries you can crimp, add layers of shapes, like those really neat stickers with space in between, you can glue other items on like rhinestones, beads, chain and so forth.

Just get creative with it.

Lets continue making this ensemble shall we?

Step 5: The Crown & Earrings

Created like the necklace, the difference is we will be using the backing style, with added support at joints.

This set was all made from the 10 mil rolled goods, if I would have used 7- mil. pouch or a 10- mil pouch it would have been very stiff and may not have required a backing. So instead of cutting 6 pieces we would only need 3.

We are using another great pattern from Silhouette.

I measured the head, 22.5" ÷ 3 = 7.5" + .25" = 7.75" ea. Piece and I want to cut 6 identical pieces. 3 for the front and 3 for the baking. The extra .25" in length is for overlapping and connecting together.

So cut the design and apply the foil just as before to 3 pieces. Then take each one and place foil side down on Teflon sheet, now place non foiled shape, glue side down on-top of the back of foiled piece, fold Teflon sheet over the shape. Be-careful not to displace the shape keeping everything lined up before adding heat once again.

This will give more thickness to the design for molding into shape. Complete all 3 pieces.

Now glue or heat the sections together, a heat gun can help form shapes, be careful don't get burned.

Now the 3 sections are together, you can add all the finishing touches you like. This one is just simple, one little rhinestone in the front and a chain draped around the edges. Make a couple earrings to match, from leaf clippings add a little jewel. Complete ensemble.

The next few sections are just some steps in the processes like adding glitter, and using scraps.

Step 6: Steampunk Love

Create nesting objects,using off set, then cut one more that is an outline only cut. When you cut the other piece you will need to know if it is for backing or cover. It may need to be a mirror image. You should have 3 pieces.

This design will allow you to create two different finishes that nest together. You have seen those belt buckles that have multiple metals all tooled together like filigree work; this will give you that look.

Now Foil some gear shapes, add a little antiquing and attach to a nice card and you got yourself a Steampunk loves in gear, Valentine card.

Step 7: Glittered Layered Love

We cut the word love and a mirror image cut. You should have 2 pieces . The glue sides should be face to face and match. I cut one of the loves separate from its scrolling this way each section can have its own glitter or foil color.

We pour glitter onto Teflon sheet and place one shape, glue side face down on to glitter, fold over Teflon sheet. ( Glitter is and will almost always be messy to some degree ,so don't fuss ,just be-careful ) The glitter will cling some to the Teflon sheet,just tap off what you can and then wash it off and dry) NO Problem.

Test your glitter with heat, some melt at a low temp. ( all the glitters, that were used did fine)

Apply heat ,as the glue heats up the glitter will stick just like the foil. Repeat with different color glitter for other piece . Now that the glitter work is done we place the pieces back together lay the non-glittered piece on top ,cover with Teflon sheet and heat. Finished

The Pouch material works best 5 mil - 7 mil. - 10 mil

I made some with sand,dirt,mica powders. DON'T USE EMBOSSING POWDER

GLOW -N - DARK Glitter is Awesome!