The Corroded Skin: Experiments in Surface Transformation

working with an extensive image library and utilizing both analog and digital techniques of fabrication, material studies, corrosion investigations, connection processes, transparency, and resistance; the corroded skin was partially fabricated, actualized and represented for a future facade surface.

through both analog and digital fabrication techniques the panels were fabricated by utilizing laser cut patterns that were sand blasted with image patterns that were then corroded using an ammonia and salt bath to speed up the corroded surface, presenting what the facade would look like in the future.

Step 1: The Corroded Skin: Experiments in Surface Transformation

find something that inspires you!

Step 2: The Corroded Skin: Experiments in Surface Transformation

look for some projects that you think may be similar to what you are wanting to accomplish!

Step 3: The Corroded Skin: Experiments in Surface Transformation

look for images that you think may make a good pattern!

open these images in Adobe Illustrator and live trace them!

these will function as the background to your corrosive pattern!

Step 4: The Corroded Skin: Experiments in Surface Transformation

Print out the image as a pattern, take the image to the laser cutter, laser cut the pattern out of chipboard, then use the sandblaster to blast that pattern onto your piece of copper or brass depending on the budget!

Step 5: The Corroded Skin: Experiments in Surface Transformation

Time to make a corrosive bath! Make sure to find somewhere with a vent for adequate ventilation for this is a mixture of ammonia and salt to corrode the metal! Let it sit in the bath for a while, you can check on it occasionally to see how it has progressed.

Step 6: The Corroded Skin: Experiments in Surface Transformation

And Now you have your corroded skin! The copper or brass at least! For the connectors that's the next part of the instructable!

Step 7: The Corroded Skin: Experiments in Surface Transformation

Now we're going to look at how to make those great aluminum connectors!

Step 8:

First as the photos show you need a sheet of aluminum and a print out of a template for the size of the disk that you are going to cut! Then affix that to the sheet of aluminum and make rough cuts on the band saw around the circles for the disks or for whatever shape you may want to make.

Step 9: The Corroded Skin: Experiments in Surface Transformation

The next step is to sand down the disk using a belt sander, and of course with your metal lathe you can begin to machine the parts to even finer detail!

Step 10: The Corroded Skin: Experiments in Surface Transformation

Next step in the process: sinking that center hole, as well as adding two additional holes using the drill press. For this you'll have to be accurate and set everything up very specifically, centered and precise to not go through the material - when you are countersinking the center hole and make sure to go all the way through with the next two drill holes! After that you can take it to the sandblaster and get them to have a great textured look!

Step 11: The Corroded Skin: Experiments in Surface Transformation

And there you have it, how to make the corroded brass or copper skin with digital fabrication laser cut pattern as well as how to produce the aluminum connectors. I hope you enjoyed this instructable!