Wirework Made From Old Copper Wire

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Introduction: Wirework Made From Old Copper Wire

I was delighted when I saw some wonderful wireworks on the Internet.
There was some old copper wire in the garage so I decided to make my own wirework.
It's not to hard to make something, simple shapes like flowers, cottages, trees, sun and moon...
But, I was looking for something really wonderful. How to make something realistic almost like photo. I think I've almost succeed using laser made mould.
Its a small wirework art (10cmx13cm).
Copper wire used in this presentation is only 0.5mm thick.
It is possible to make much bigger wireworks using similar method.

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Step 1: Material and Tools

Material:
Copper wire 0.5mm (5-6m)
Copper wire 1mm (0.5m)
polywood (10x13cm or bigger)
solder (tin)

Tools:
Laser cutter
Computer (and software)
Soldering iron
Drill
Plier set
Screwdriver

Step 2: Theme, Art, Motive

It's basically an art so it's crucial think what will you create.
I choose a picture of my son.
I love him very much and it was the biggest motive to finish this wirework art.

Step 3: File Preparation

File preparation is process from the original jpg picture to the vector graphic.
I've used Xara Extreme to do it.
Althow you can do that as a graphic designer it isn't necessary. You can just chose the detail you want and your engraver can do the rest.

Step 4: Lasering

Choose a polywood piece and let the laser cutter cut the piece.
In this case wire is thin and it is not necessary to do double cut.
For thicker wire it's necessary to cut two lines to create appropriate channel.
( For 2mm wire - 2mm channel)
Vertical or (and) horizontal lines are assigned to hold main picture.

Step 5: Fixing the Wire Into the Channels.

Put the wire on the channel and fix it into the gap.

Step 6: Soldering the Main Picture

Solder joints.

Step 7: Drilling Holes for Horizontal Wires

Drilling holes for horizontal wires.
It should be done by laser cutter but unfortunately I've forgotten that.
It's never late to do that.

Step 8: Horizontal Lines

Horizontal lines hold the main picture.
Solder them too.

Step 9: Separation

It's a moment to separate mold and wirework.

Step 10: In This Case a Simple Frame.

In this case a simple frame made from copper wire

Step 11: Soldering Wirework Art on the Frame

Soldering wirework art on the frame.

Step 12: Your Wirework Art Is Over.

Your wirework art is over and ready for some appropriate frame.
You can paint it or just hang it on the wall.
Your polywood mold is ready for another copy.
You can make as much copies as you like.
I hope you've found some useful information in this instructable.

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    12 Discussions

    0
    Marco Fragomeni
    Marco Fragomeni

    10 years ago on Step 3

    Hello, I would like to try this great Instructable, but i do not know how to obtain the converted image from the jpeg photo. could you tell me the steps? i will use Xara Xtreme 5. thanks a lot for sharing

    0
    lemonie
    lemonie

    10 years ago on Introduction

    It needs to be connected to a high-voltage supply for some corona-discharge! (great) L

    0
    The Jamalam
    The Jamalam

    Reply 10 years ago on Introduction

    combine this with the plasma speaker from plasmana and you've got yourself an awesome!

    0
    lemonie
    lemonie

    Reply 10 years ago on Introduction

    Yea, that's the sort of think I was thinking of. L

    0
    lemonie
    lemonie

    Reply 10 years ago on Introduction

    I hadn't thought of that - good idea - dead bugs on your son's portrait... L

    0
    valhallas_end
    valhallas_end

    Reply 10 years ago on Introduction

    True, true. Where I live though, anything with live current has to be sanctioned by a safety officer - a neighbor was fined $500 for building a Jacob's Ladder in his backyard when a cop just happened to see through his chain fence. A bug zapper would be a great cover...plus, it would help with the "mad scientist" vibe.

    0
    lemonie
    lemonie

    Reply 10 years ago on Introduction

    Wow, that strikes me as a bit oppressive. Where do you live?! L

    0
    valhallas_end
    valhallas_end

    Reply 10 years ago on Introduction

    Central New York, but granted they do have good reason. Lots of fires in my town were caused by people putting fire pits, garden torches, grills and the like too close to houses, which started the sanction laws. But when a huge windstorm dumped branches onto electric dog fences (older style, not well regulated) and electric lamps and caused leaf and grass fires, they took it further. In most places it would be a bogus law, but my village only has a volunteer fire department (the neighboring villages are a bit snobbish on lending their coverage), so it does make sense.