Heads up: I'm not the first person to do try to do this - if you want to be entertained with some good lulz you should check out the OG steel toed crocs from I did a thing: ua-cam.com/video/29iC6RlbL7s/v-deo.html
My 2 cents 1st, You are damn good in what you are doing and I loved your video 2) I would take that wood block shapes and cast aluminum blocks from them that will be much cheaper to do if you use some scrap alu for the job. A home alu casting setup cost next to nothing and that will expend your visions unlimited.
This guy does a thing and the metal doesn't fold. ua-cam.com/video/p_hb-KfuB6M/v-deo.html Don't know if this helps. Also, in manufacturing they often pre-bend the sheet metal to help hold it in the die, as well as align it properly. Maybe a combination of dies would work better?
The key to avoid the folding is to make it in steps, increasing the depth of the mold each time. I think there is even theoretical formula to know how many steps you have to do.
The alternative is more force. If you clamp with 50ton, it doesn't slide as much, the metal stretches more around the form. So more lube, and clamping force will help. Second the time taken to press affects the amount of stretch v slip.
I'm so addicted to this channel. The fact that failure is the process helps me in my every day life. Everything about the format of this channel is amazing. Thank you
@thomas robinette Only because if you didn't claim to know what you are doing, could you really call yourself an expert programmer? Let's be honest here, even as an "expert" do you really know unequivocally what you are doing all the time or do you still have to fumble through till you get to the right idea sometimes too?
I used to work in an automotive press shop. We made parts for BMW. From my experience I can tell you that pressing the part in one go is not the best method. The way the presses worked in the automotive field is that they used a step method. The part was stamped out bit by bit using large rolls of sheet metal. The stamp would come down on one part of the metal & make a shape into it. Then the moulds would open up on top & bottom & the sheet metal would me moved along to the next stamp. So on & so forth until the final part was clipped off at the end of the run. This would prevent the metal from buckling & would provide a nice consistent form The extra scraps of metal would fall off into a conveyor system where it would be routed to a metal collection bin that would then be remelted & reformed into new sheets of metal. Nothing went to waste.
It's really interesting to look back at this video from just a few years ago and note how much Shane has built up his chops as, honestly, an entertainer.
@@IntoDeathandTheBuddahMatrixcomments are generally understood to be more conversational and i think a lot of people just type how they talk. i certainly do. anyway i hear people say “honestly” like this all the time so i hope you’ve gotten over this
3:06 "it took me four or five generations to get this tool mostly working" _the project had begun with my grandfather's grandfather... we know no longer why we toil in the fabrication of this instrument so hideous, but such is our charge_
Reminds me of how it took so many generations of cartographers from the same family to map out France, and then when they were done, they found out France's area was smaller than their original estimate lol
I did that while seeing a movie with my girlfriend a few years ago.. there was an underwater scene and I was eating popcorn and when they surfaced and took a deep breath I did too and I inhaled popcorn and started choking really badly. She saved my ass and when everything calmed down she asked wtf happened and I explained and she was like "Wtf... you're an absolute fucking moron." I was like "Nooo! The movie was just super immersive. They did their job. So did I. I stand by my near death experience." I still do. I'm now single. No regrets!
I'm surprised no one in the comments has mentioned "draw beads". Draw beads are bumps overwhich the metal is pulled on the edge of the form to put resistance to pulling it in. Not stop it from pulling it in, just resistance, so that the metal is under a lot of tension, which helps it stretch better without wrinkling. Go look it up. As a student, I once worked in a research lab that investigated the effect of different lubricants on draw bead friction. The auto industry spends a lot of money on this.
@@bubba7849 Yeah, it would reduce the elasticity of the metal, therefore a larger strain with a smaller stress, aka it will just deform more with less force, as heating the metal would increase atomic kinetic energy, increasing the interatomic distance and thus the interatomic forces decrease - allowing for the metal to be more ductile and this characteristic determines how well the metal deform s under stress. Quite fascinating how heat can be used to harden metals as well as soften, and both have so many uses.
@@bubba7849 Ask a blacksmith or an armorer. We deal with this sort of stuff all the time. Even hot metal thickens on the inside edge and thins on the outside edge when bent. Look up some videos on chasing and repousse...you will see how it is done old school.
So it looks like that would be similar to what he did at 11:48, minus the actualbead part. As a current engineering student who enjoys your videos, I'm curious what did you go to school for?
One of the easiest ways to help control the buckling or wrinkles is to remove material from the area. Put a semi-circular cut-out in the areas with the wrinkling. Less material in the area of the wrinkling gives all that "extra" material somewhere to go with folding over. Experiment with how big the semi-circle should be to make sure that the edge of the circle isn't pulled into a part of the final shape that you care about. Depending on the exact contour, this may lead to the wrinkles forming in the toe portion rather than the clamped area. As Matthias mentioned, draw beads are a huge help in cases like this, especially since you have the capability to machine them in. Since the bead touches the sheet metal first, as you clamp the die together it will hold that area in place and force more of the surrounding metal into the form. This helps spread the distribution of material that you're pulling so that it's not just all the "easy" material at the wrinkle point. More resistance to movement means less flow of material, but be careful not to clamp it too severely or the sheet metal will neck down and eventually split.
I love that you make engineering look so attainable to the average mind. You show that it’s okay to fail (so long as you have the materials lol) and that with the right attitude, you can make anything
Really he could probably do it quite well with one tool that has both left and right in a sort of kidney shape. He already added that extra lump on the back to balance the form, might as well make that off cut lump useful.
As a mechanical engineer, I think it's pretty cool to see how you iteratively come to a process that's very similar to standard drawing and forming presses! Especially that hold-down plate to prevent material bunching up during the drawing step. Kudos! 😀👊🛠️
Oh, and there's a good chance by now that you're already aware of this process and this comment is superfluous, but check out sheet hydroforming. You only need one side of the blanks, cover it with a (tightly clamped) sheet of metal, which is forced onto the blanks by some construction involving generally a rubber diaphragm or bellows. It's pretty cool! 😊
The first form dies were made out of wood, and they were used in smith shops. It could be argued that the first mass production elements (scaled for the day) were made in there.
Is it only a coincidence that this channel looks like it's going to be the second sub 1 year old channel I've found in the early stages of massive channel growth, and they've both made videos about steel toed Crocs? I don't think so.
Yeah, i was thinking he would have had a lot more success if he tried to do both in one press, like a kidney bowl. I think you would get a better form because the pressure would be spread over a larger surface area.
11:05 , 13:48 , 16:16 , 17:38 love watching the creases form. Its so cool to think how many things deform in this way- clothing when you bend your knees and elbows, towles hanging on a rack, paper you crumple up, etc; all follow the pattern of buckling/folding. I guess this must be the cheapest way for the universe to deform flat surfaces or something? Its so cool
This was very interesting to watch, especially as a tool and die maker! Loved watching the trial and error! It's honestly the best way to learn. Draw dies are definitely the most complicated dies to design! Impressive even more still as you were able to accomplish this using wood! Love this channel! I think I've watched all your videos now! Looking forward to seeing what's next!
I love seeing your iterative process, and I totally relate with this sort of side project that is maybe a little bit useless, but still teaches you a lot about a process that you can carry forward.
You are so right about this part 15:32. In designing stuff you have to ambrace failure. I know it can be hard for some but I would say to become a good designer in general one must to learn to fail fast to get to the end goal. We shouldn’t spend too much time trying to think if the prototypes along the way are finished or not becouse we just want the end product to work. Embracing failure is one of the ten design heuristics I live by and apply it to my own business
Your problem-solving skills are really impressive, it would be cool if you could share more of your background (how you learned all of this, if you studied at university, etc.)!
@@bruce-le-smith I heard in one of the videos that he was the engineering leader of a couple of projects, like 3D printers, in a company. so he definitely has a solid engineering background
Wighton attended the University of North Carolina at Charlotte, where he received a Bachelor’s degree in Mechanical Engineering and a Master’s degree in Computer Science. Wighton formerly led an engineering team at Formlabs that makes 3D printers that utilize stereolithography (SLA) and Selective Laser Sintering (SLS) technology. He is an inventor on five patents and 13 pending applications. -Wikipedia
I did pneumatic forming with wooden forms in my college metalworking class. Annealing the metal, bolting it to the form, and then hardening it afterwards makes the process SO much easier. That lets the metal actually stretch and form, and then you can harden and temper it however you want at the end.
3 things you might want to look into the next time: blank shape has a big impact (doesn't need to be square - might be squiggly shaped). To get rid of wrinkles, you want to stretch the material OUTSIDE of the final part you want to make. Blank holding is actually quite important (draw beads, clamp force, bla bla bla). I love how you got actually nice quality parts from such a simple tool . I really really like how you get to your result and that you show the iterations.
I used to think like this. Then I realized, if you don't know history and you come up with an idea like this, then you are basically inventing that idea just as the original inventor did.
Michael Brown, you'll notice there's over 90 thumbs up to your post. Seems like a lot of us favour Crocs as preffered footwear in the shop. I certainly won't be out there wearing these👠👠
I've made (heavy) fiberglass dies to do steel and aluminum pressings. I've pressed pieces up to two square feet. I have a large-platen 100 ton press. It's mostly a matter of location and keeping the material in place with pins. One thing that makes the pressing easier is to use low strength "tryout" steel. Only about 30kpsi yield, so it forms easily.
Nice work. Lesson to be learned from WWI. German helmets stopped bullets. Ours did not. Multiple pressings. Each going a little deeper, each time. Plus soapy water. This led to a more even wall thickness. So bullets to the forehead, temples, etc .... were stopped. Maybe that would fix your issue w/ folding/bunching up. I look forward to seeing more of your work!
Just now i realize that i don't actually know what TOT looks like. I guess he does such a good job at being an enjoyable guy that he makes you feel like you've known him for a lifetime so you just stop questioning stuff like that and you just enjoy hanging out with your faceless, nameless buddy for around 30 mins or so.
@@rauldragu9447 It's just not important with these types of creators, generally you identify them more by their hands...that being said, you can see Tony in the "Stress, Strain & DIY Tool Holder" video.
Some thoughts I had mid way through the video: Would it be of any use to prototype molds with thinner gauge metal, or even aluminum foil? Perhaps adding some relief cuts in the blank would remedy the “bunching up” problem Maybe you could try forming metal preheated in an oven or use annealed stock
I’m just a lowly woodworker, but my engineering degree helps me see the genius in this man. You sir, are inspirational. Also, the way you include your wife gets the approval of my wife, and now she watches with me. Thanks for sharing. My kids will be shown you as an example of how cool it can be to be smart and capable with your hands.
Die design is a fickle beast. Easily as much art and intuition as science. I must commend you. You have wrapped your head around draw die concepts that take years for some die design engineers to grasp. And you’ve done it with a Chinese press and some scraps of wood!! As far as showing your face on camera...I’d say whatever makes you more comfortable and doesn’t interrupt you workflow too bad.
So I make my own custom bending and forming jigs out of steel for mass production.. this is really exciting seeing how someone else makes their forms.. the more you make these forms it will become second nature where it usually works after the initial idea..
As a professional UA-cam viewer, I really like how you do the mini-videos at the bottom to show us the minor tasks (like 14:45). You have a very good intuition about video pacing to keep our attention.
That basically men’s decision making 101. :D Why are we having McDobalds for dinner? Well my wife was asleep. Why is you daughter eating so much candy? Well my wife was asleep
I come from aircraft engineering so I’m more of an aluminum guy, but we would typically use annealed stock for a formed part with radii that tight, and then use the work hardening itself or tempering to hit specs. I’d reason that you would still run into some issues if you fully annealed the stock at the start just based off the gauge you’re going with, but if you started with an initial rig that is similar to what you have going, I’d say you could take it three quarters the way to your ideal shape and avoid buckling. From there you could trim to your final dimensions, hit it with a quick torch anneal (benefits of it seeing a croc and not an aircraft haha), and then pop it into a final forming block (a registration pattern of some sort would be helpful) that would set your final dimensions and work harden it back to steel toe territory. Would hopefully avoid a lot of springback related calculations, and would mostly just give you an excuse to put a mirror polish on those bad boys! Anyways, just figured I’d throw my hat into the ring! Who doesn’t love a little armchair manufacturing engineering? 😂 Love the videos!
@@stockphotosguy6037 when you bend or harden metal, you leave a lot of stored stress in the metal. Stored stress makes metal hard, which also makes it difficult to bend. Making the metal really hot, keeping it hot for a while, and then letting it cool really slowly gets rid of the stored stress. With less stress, the metal is easier to bend. The process of heating, holding, and slow cooling metal to remove the stored stresses is called annealing. There's actually more to it involving the crystal structure of the metal, but that's the easiest explanation for layman's terms.
@@prestonshaw5391 Not really disappoint. Though I did a thing usually doesn't care about the end product, his videos are for the purpose of entertainment(so the end product tends to be bad because that looks funny). Which is totally fine. His focus is just shifted towards entertainment and I have to say that I did find his videos very entertaining.
i know this video is months old and you may not read these, but i appreciate when you look into the camera while explaining something because it seems easier to focus on what you're explaining
So what you are doing is soft forming.... in a way, just a tip, your "tool" is pt so its harder than your punch, the crop form in other words. Add a 90° bend to the outside of the stock use that bend as a clamping area that will force the material to stretch rather than pull. If the material pulls you'll have some good and some bad parts. Try AMS 5510 around 30 thousands. With my suggested method in combo with your methods you should have a 25-27. Thousands thick steel toe. I did a lot of forming,machining, and sheet metal work but thus I enjoyed the video! One more recommendation is pick 2 different materials. One vastly stronger than the other. I recommend using pressure treated for the punch, and steel for the tool. Ideally heat treat your tool steel to prevent wear and tear
Is my understanding correct in that you want to make the material thinner rather than drawing it in from the sides? I can see that drawing the sheet to be smaller in length would easily make creases.
As someone who left an engineering path to pursue custom fabrication, I really enjoy watching your approach and perspective. Couple of insights from my experience, in case they might be helpful - MDF to make your bucks. It's much more predictable, leaves a better surface on thin/soft, and just the right amount of conformity on the edge for
I like the no face “ala young tony” style. And also like this old tony videos I watched the whole 24 minute with a smile. Even tho I don’t know why, it’s a asset for a croc for f*ck sake. Great work
We had a whole storage room filled with hand made wooden forms for sheetmetal. Made forming complicated parts a whole lot easier and simple, hammer it to form and you're done.
Great video! I think I'm late to suggest, but the tools need a stripper plate. Stripper plates will be connected to the top plate with springs which exert force on the sheet before the top punch makes contact with the sheet. This way the sheet flows uniformly because of the resistance/force exerted by the stripper.
As a professional UA-cam viewer, I really like how you do the mini-videos at the bottom to show us the minor tasks (like 14:45). You have a very good intuition about video pacing to keep our attention.
I’m not sure of the condition of the sheet metal when you start, but I’m thinking annealing the steel first to soften the alloy to reduce spring back and allow the steel to more easily stretch during forming. If it is too soft for proper foot protection after forming it could be tempered to a spring temper if it has sufficient carbon content.
So very interesting! Great video! while using a press with a die when we make the shape of a fuel tank we spray a little grease on the sheet of metal so the metal don't rankle or tear ...
Hello, i may be a little late on this comment, but on your wooden press, wood is realy good at handelling compression, as long as the compression happends in the dirrection of the grains, think of them like a bundle of matches, if you press down on the tip of a match, it wont brake that easy, but if you press down at the side of a match it snaps. its the same thing with the wood itself. So if you try to mass produce steel toad crocks in a wooden press, keep that in mind.
One suggestion: You could design it so that you purposefully allow crumpling to happen at the back end (the part that you are going to cut off anyway) so that all the pressure will be dissipated to that spot making the parts that matter crumple less.
Thanks for sharing this, I really enjoyed watching the iterations you went through. Thanks again much appreciated. What if something happened to fall and land at the back edge of the steel, could (or would) it fold down into your croc/foot? How heavy would something have to be for that to happen? I’m interested because I have a cautionary tale. I was in a shared art studio with several people working on different metal sculptures and related projects. Everyone was meant to be wearing steel capped boots (made to the Australian safety standards), but one dude had purchased a cheap pair. So anyway, he was cutting a big sheet of metal with a gas-axe, had the piece to be removed hanging over the edge of the workbench and….yeah, that large piece of metal (about an inch thick and approx 2foot x 1 foot) it fell down and landed right on the back edge of the steel toe, the steel toe insert bent down and cut into his foot, sliced off 2 toes and almost severed the others. It was a great day for everyone obviously 🙄. Long story short (er) Everything was (kinda) okay in the end, lots (and lots) of blood and lots of tools in the studio available for the paramedics to cut off the boot (Gag) And off to the hospital with toes in a bag that were then put inside another bag filled with ice. All toes except for one were saved. Soooo, LESSON LEARNT. Don’t be a cheapskate with safety gear…just don’t..NO. Also - Safety was drastically improved, footwear inspected prior to ANY studio access. No appropriate footwear, no access. Apologies for the overshare, but the mention of steel toes, always makes me think about that damn “back edge” and it’s guillotine potential - awesome I know. 🙂🐿
@@nikkiofthevalley oh for sure, it was really obvious upon inspection (and he admitted to it) that he had purchased basically a fake pair of steel caps. Hence the cautionary tale. It’s frightening to think that people will manufacture fake safety equipment, but given the mark up, not totally surprising either.
I had a lot of similar learnings here when I was doing my first upholstery. Wrapping fabric around a surface curved multiple directions has similar challenges with bending. The solution there was to cut triangles all the way up to the edge of the fabric, which allowed for the material to bend different ways without folding over on itself. I’d be curious if making a similar cutout in the metal blanks would allow the same here, potentially reduce the number of shaping steps required.
@@christopherbelmonte5145 It's a lot more complicated than that. It would be more accurate to say that wood is expensive because demand went up because of home improvement projects spurred by quarantined people staying home, and lumber mills running under capacity due to a lack of labor
Heads up: I'm not the first person to do try to do this - if you want to be entertained with some good lulz you should check out the OG steel toed crocs from I did a thing: ua-cam.com/video/29iC6RlbL7s/v-deo.html
My 2 cents
1st, You are damn good in what you are doing and I loved your video
2) I would take that wood block shapes and cast aluminum blocks from them that will be much cheaper to do if you use some scrap alu for the job.
A home alu casting setup cost next to nothing and that will expend your visions unlimited.
This guy does a thing and the metal doesn't fold. ua-cam.com/video/p_hb-KfuB6M/v-deo.html Don't know if this helps. Also, in manufacturing they often pre-bend the sheet metal to help hold it in the die, as well as align it properly. Maybe a combination of dies would work better?
You know you have to make him a pair and send it to him now.
I did a thing is one of my favourites he is strange Aussie but very humorous
be the first to do it with kevlar :) easyer to shape, might even work - then the outside can be fully covered, you just want the croccy insides anyway
Nice Shane! Great to see the whole learning process.
it's great that you support him
Do you know him personally mark?
Hi Mark!!!
how does Mark rober only have 50 likes and 3 comments lmao also weird that Mark rober sounds like mars rover....
69th like
Mate, we should have a dance off!
How is this not getting more attention?
@@quadrupleheart no clue
I did a thing saw your video too
bruh, a crock dance party
Love your vids
The key to avoid the folding is to make it in steps, increasing the depth of the mold each time. I think there is even theoretical formula to know how many steps you have to do.
Like how aluminium cans are made!
Yea you need to look up a cold working formula to find the number of steps.
@@thatsomeone3818 but he wants to do it in one press because…. It’s faster!
The alternative is more force. If you clamp with 50ton, it doesn't slide as much, the metal stretches more around the form. So more lube, and clamping force will help. Second the time taken to press affects the amount of stretch v slip.
I'm so addicted to this channel. The fact that failure is the process helps me in my every day life. Everything about the format of this channel is amazing. Thank you
It's amazing how much your life will change when your relationship with failure changes.
@@michaelkappel8224 honestly
"I never claimed to know what I'm doing... I just know what I'm trying to do"
Oddly profound. I like it
being a beginner programmer, I live by this, it even happens like that when im working with my dad on home repairs/remodeling
@@dragojuice8716 as an intermediate programmer i also rely on it lol
@@guywith_dog as an expert programmer I have abandoned this and now I do claim that I know what I'm doing.
My life story 😂
@thomas robinette Only because if you didn't claim to know what you are doing, could you really call yourself an expert programmer? Let's be honest here, even as an "expert" do you really know unequivocally what you are doing all the time or do you still have to fumble through till you get to the right idea sometimes too?
*at job interview*
"Oh I heard you've done some projects of your own! Care to share them?"
*Lifts foot into table*
S t e e l - t o e d c r o c s
I'm hiring you just so I can fire you.
Hire 100
"Give this man the the job, this is revolutionary!"
same energy as Flint from Cloudy with a Chance of Meatballs
Eid spray on shoes
I used to work in an automotive press shop. We made parts for BMW. From my experience I can tell you that pressing the part in one go is not the best method. The way the presses worked in the automotive field is that they used a step method. The part was stamped out bit by bit using large rolls of sheet metal. The stamp would come down on one part of the metal & make a shape into it. Then the moulds would open up on top & bottom & the sheet metal would me moved along to the next stamp. So on & so forth until the final part was clipped off at the end of the run. This would prevent the metal from buckling & would provide a nice consistent form The extra scraps of metal would fall off into a conveyor system where it would be routed to a metal collection bin that would then be remelted & reformed into new sheets of metal. Nothing went to waste.
It's really interesting to look back at this video from just a few years ago and note how much Shane has built up his chops as, honestly, an entertainer.
I thought the same
The use of honestly is awkward and unnecessary. Adverbs modify verbs, adjectives, and adverbs. The adverb is not modifying anything.
@@IntoDeathandTheBuddahMatrix idiot
@@IntoDeathandTheBuddahMatrixcomments are generally understood to be more conversational and i think a lot of people just type how they talk. i certainly do. anyway i hear people say “honestly” like this all the time so i hope you’ve gotten over this
"I never claimed to know what I'm doin'. I just know what I'm trying to do."
Words to live by 😂
This needs to be a shirt!
Best quote in a while tbh
This is such a good quote
3:06 "it took me four or five generations to get this tool mostly working"
_the project had begun with my grandfather's grandfather... we know no longer why we toil in the fabrication of this instrument so hideous, but such is our charge_
this comment is underrated
i laughed so hard LMAO
LMFAO
Reminds me of how it took so many generations of cartographers from the same family to map out France, and then when they were done, they found out France's area was smaller than their original estimate lol
Ha said iterations 🤣
Read this in Werner Herzog's voice, and it's 100x better.
wait until he finally realizes he has to make a left croc
@16:40 Love that line, "I never claim to know what I'm doing, I just know what I'm trying to do." You've summed up almost everything I've ever done.
when that weight fell off at the shelf at 0:17 , I instinctively moved my foot and stubbed my toe into my desk...
same, wtf bro, I've been getting this more lately with similar video footage and I never did before. Is my brain growing more stupid as I grow old?
Wouldn't that mean you moved your foot into the way?
I wonder what actually happened after the cams cut
I did that while seeing a movie with my girlfriend a few years ago.. there was an underwater scene and I was eating popcorn and when they surfaced and took a deep breath I did too and I inhaled popcorn and started choking really badly.
She saved my ass and when everything calmed down she asked wtf happened and I explained and she was like "Wtf... you're an absolute fucking moron." I was like "Nooo! The movie was just super immersive. They did their job. So did I. I stand by my near death experience."
I still do. I'm now single.
No regrets!
Wouldn't have happened if you were wearing steel-toed Crocs!
I'm surprised no one in the comments has mentioned "draw beads". Draw beads are bumps overwhich the metal is pulled on the edge of the form to put resistance to pulling it in. Not stop it from pulling it in, just resistance, so that the metal is under a lot of tension, which helps it stretch better without wrinkling. Go look it up. As a student, I once worked in a research lab that investigated the effect of different lubricants on draw bead friction. The auto industry spends a lot of money on this.
You should get verified too Matt.
Wouldn’t heating up the sheet metal work aswell?
@@bubba7849 Yeah, it would reduce the elasticity of the metal, therefore a larger strain with a smaller stress, aka it will just deform more with less force, as heating the metal would increase atomic kinetic energy, increasing the interatomic distance and thus the interatomic forces decrease - allowing for the metal to be more ductile and this characteristic determines how well the metal deform s under stress.
Quite fascinating how heat can be used to harden metals as well as soften, and both have so many uses.
@@bubba7849 Ask a blacksmith or an armorer. We deal with this sort of stuff all the time. Even hot metal thickens on the inside edge and thins on the outside edge when bent. Look up some videos on chasing and repousse...you will see how it is done old school.
So it looks like that would be similar to what he did at 11:48, minus the actualbead part. As a current engineering student who enjoys your videos, I'm curious what did you go to school for?
One of the easiest ways to help control the buckling or wrinkles is to remove material from the area. Put a semi-circular cut-out in the areas with the wrinkling. Less material in the area of the wrinkling gives all that "extra" material somewhere to go with folding over. Experiment with how big the semi-circle should be to make sure that the edge of the circle isn't pulled into a part of the final shape that you care about. Depending on the exact contour, this may lead to the wrinkles forming in the toe portion rather than the clamped area. As Matthias mentioned, draw beads are a huge help in cases like this, especially since you have the capability to machine them in. Since the bead touches the sheet metal first, as you clamp the die together it will hold that area in place and force more of the surrounding metal into the form. This helps spread the distribution of material that you're pulling so that it's not just all the "easy" material at the wrinkle point. More resistance to movement means less flow of material, but be careful not to clamp it too severely or the sheet metal will neck down and eventually split.
I love that you make engineering look so attainable to the average mind. You show that it’s okay to fail (so long as you have the materials lol) and that with the right attitude, you can make anything
when he realizes he has to make another tool for the left foot
Underrated
Just mirror it
I guess just break the left foot to the right
Shhhhhh... Don't tell him yet, he can figure it out on his own. His IQ is bigger than Mount Everest, he'll figure it out.
Really he could probably do it quite well with one tool that has both left and right in a sort of kidney shape. He already added that extra lump on the back to balance the form, might as well make that off cut lump useful.
"I've now succeeded in making 2, pretty ugly pieces of garbage"
yeah my mum said the same thing.
Nice m8
True
I'm going to assume you have one or two terrible siblings. 😈😎
Who is the second one?
lol
As a mechanical engineer, I think it's pretty cool to see how you iteratively come to a process that's very similar to standard drawing and forming presses! Especially that hold-down plate to prevent material bunching up during the drawing step. Kudos! 😀👊🛠️
Oh, and there's a good chance by now that you're already aware of this process and this comment is superfluous, but check out sheet hydroforming. You only need one side of the blanks, cover it with a (tightly clamped) sheet of metal, which is forced onto the blanks by some construction involving generally a rubber diaphragm or bellows. It's pretty cool! 😊
The first form dies were made out of wood, and they were used in smith shops. It could be argued that the first mass production elements (scaled for the day) were made in there.
History ... Not studied any more!
Outta take a gander at ‘I Did A Thing’ and his steel toed crocs
Dont mine are embarrassing compared to this.
@@Ididathing Lol you replied
Is it only a coincidence that this channel looks like it's going to be the second sub 1 year old channel I've found in the early stages of massive channel growth, and they've both made videos about steel toed Crocs? I don't think so.
I did a thing LMAOOOOO hey 👋
@@Ididathing hows the lizards
The sad part is that each tool is only for a right croc
Yeah, i was thinking he would have had a lot more success if he tried to do both in one press, like a kidney bowl. I think you would get a better form because the pressure would be spread over a larger surface area.
OMG you're right or is that correct.
The left foot is never in danger, so I don't see a problem
Part two is probably a mirrored version of this video
Not to mention one particular size shoe
I love how this channel is the epitome of overengineering. Mid-video I realised this would probably take a few hours for a blacksmith to make.
Or composite a fiberglass toe right onto shoe.
nah he copied i did a thing
And was the stuff that were made.. free to begin with?
Every weight of the craftsmanship .. cost more than a penny!
@@mcbawangyakuznouxman9439 Ironically most of the expensive tools in Shane's shop were gifted to him
11:05 , 13:48 , 16:16 , 17:38 love watching the creases form. Its so cool to think how many things deform in this way- clothing when you bend your knees and elbows, towles hanging on a rack, paper you crumple up, etc; all follow the pattern of buckling/folding. I guess this must be the cheapest way for the universe to deform flat surfaces or something? Its so cool
“ I don’t know what I’m doing, I just know what I’m trying to do.” Needs to be on a shirt yesterday 😂😂
where is this quote? It's fantastic
@@fredrikstal1968 16:40
For real
I'd buy that, and I don't really buy merch much.
unfortunately im broke so i cant sell this lol
"Projects are the star of the show, I'm just the host." That is probably the best quote ever
This was very interesting to watch, especially as a tool and die maker! Loved watching the trial and error! It's honestly the best way to learn. Draw dies are definitely the most complicated dies to design! Impressive even more still as you were able to accomplish this using wood! Love this channel! I think I've watched all your videos now! Looking forward to seeing what's next!
a tool and what maker
I love seeing your iterative process, and I totally relate with this sort of side project that is maybe a little bit useless, but still teaches you a lot about a process that you can carry forward.
"Can wood form steel?"
Blacksmiths making armor a few centuries ago: 🤨
Few more like a couple dozen
Ik its a joke
@@omegachadrequiem3831 shut
IIRC, sheets of different hardness rubber is used over steel forms to achieve many pressed forms.
@@proudtitanicdenier4300 no karen
Next video: "Crocs™ sued me for 7million dollars"
"Crocs sued me for designing a new product for them."
Crocs would like to know your location.
Then stole my product idea
You are so right about this part 15:32. In designing stuff you have to ambrace failure. I know it can be hard for some but I would say to become a good designer in general one must to learn to fail fast to get to the end goal. We shouldn’t spend too much time trying to think if the prototypes along the way are finished or not becouse we just want the end product to work.
Embracing failure is one of the ten design heuristics I live by and apply it to my own business
You might try annealing the metal before pressing it into the form. The metal will stiffen up as soon it is pressed into the form.
Your problem-solving skills are really impressive, it would be cool if you could share more of your background (how you learned all of this, if you studied at university, etc.)!
Oliver swack he's definitely using engineering terminology throughout this video
@@bruce-le-smith I heard in one of the videos that he was the engineering leader of a couple of projects, like 3D printers, in a company. so he definitely has a solid engineering background
Wighton attended the University of North Carolina at Charlotte, where he received a Bachelor’s degree in Mechanical Engineering and a Master’s degree in Computer Science.
Wighton formerly led an engineering team at Formlabs that makes 3D printers that utilize stereolithography (SLA) and Selective Laser Sintering (SLS) technology. He is an inventor on five patents and 13 pending applications.
-Wikipedia
I did pneumatic forming with wooden forms in my college metalworking class. Annealing the metal, bolting it to the form, and then hardening it afterwards makes the process SO much easier. That lets the metal actually stretch and form, and then you can harden and temper it however you want at the end.
I was thinking this throughout most of the video! 😂
I had this same thought! Big fat sooty flame, spreads out the molecules, forms like butter. At least aluminum does. 😂
7:22 “I’ll leave it as an exercise to the viewer”
sudden ptsd from college textbooks
Remember this guy when he spent his days mass producing steel toed crocs, and I was here to watch along. See you when you hit a mil subs.
J
J
Same bro
"I'm not made of money"
**has his own CNC mill**
@Gavin Cooke so you could get Shane's joke but not OP's. Impressive.
@Gavin Cooke yes it was. pretty overused joke format too.
@Gavin Cooke well then it looks like the joke went over your head. Congrats, you played yourself.
@Gavin Cooke nah im good. get a better sense of humour ig.
@@banana13775 Jesus Christ, you are acting like a pretentious clown.
YOU are the star of the show! You literally make everything happen and escalate it to a higher level its just amazing 👏 love your videos never stop 😇
3 things you might want to look into the next time: blank shape has a big impact (doesn't need to be square - might be squiggly shaped). To get rid of wrinkles, you want to stretch the material OUTSIDE of the final part you want to make. Blank holding is actually quite important (draw beads, clamp force, bla bla bla).
I love how you got actually nice quality parts from such a simple tool . I really really like how you get to your result and that you show the iterations.
Why did I watch this?
UA-cam: Did you enjoy it?
Well, yes... but...
UA-cam: You're Welcome.
So true
If you don't know what's in infinity how can you effectively search through it y'know
Me
I used to think like this. Then I realized, if you don't know history and you come up with an idea like this, then you are basically inventing that idea just as the original inventor did.
"i want to wear my crocs in the shop and not smash my feet"
me: "OMG Finally, I'm not alone!"
Michael Brown, you'll notice there's over 90 thumbs up to your post. Seems like a lot of us favour Crocs as preffered footwear in the shop. I certainly won't be out there wearing these👠👠
There is definitely steel toe cap crocs. Google it
@@snack4458 I've been looking out for steel toe crocs for years, googling it only produces a few DIY results, nothing mass produced.
What about Birkenstock A 640?
Howard Osborne I don’t actually work in a shop at all but I believe I would prefer crocs if I did.
Hes changed so much in the last year
I've made (heavy) fiberglass dies to do steel and aluminum pressings. I've pressed pieces up to two square feet. I have a large-platen 100 ton press. It's mostly a matter of location and keeping the material in place with pins. One thing that makes the pressing easier is to use low strength "tryout" steel. Only about 30kpsi yield, so it forms easily.
Nice work.
Lesson to be learned from WWI. German helmets stopped bullets. Ours did not.
Multiple pressings. Each going a little deeper, each time. Plus soapy water.
This led to a more even wall thickness. So bullets to the forehead, temples, etc .... were stopped.
Maybe that would fix your issue w/ folding/bunching up.
I look forward to seeing more of your work!
Rare to find a golden comment like this, most are just fake backpats
Weren’t helmets for shrapnel, not bullets
@@darkfyy independent of the cause, if your helmet gets a hole...
You're having a bad day...
@@darkfyy depending on caliber, distance, etc. The idea is wall thickness. Being more even through the item. And how they managed to make that happen.
it's always german engineering 😆
Literally every comment from the hoop video: “you should mass produce this”
This guy: “I’m going to mass produce steel toed crocs”
"You should mass produce it" said everyone that would never buy it.....
Great job Shane! This was super interesting being able to watch the entire process.
Usually it's advised to lubricate the seel sheet + the steel top and bottom plates, and the mold, to reduce creasing. And probably springback too.
8:42 my parents after having me as their second child
Lmfao got me dead 💀
Hahah thank you for this. Made my day
I belly laughed for a minute straight with this comment. 😂🤣😅☠️
Best laugh I've had in a while. 🤣
Lmfao irl
Faceless is fine to me 🤷🏾♂️
Your projects are stars on their own. I call you The Young This Old Tony. Keep going.
Just now i realize that i don't actually know what TOT looks like. I guess he does such a good job at being an enjoyable guy that he makes you feel like you've known him for a lifetime so you just stop questioning stuff like that and you just enjoy hanging out with your faceless, nameless buddy for around 30 mins or so.
@@rauldragu9447
It's just not important with these types of creators, generally you identify them more by their hands...that being said, you can see Tony in the "Stress, Strain & DIY Tool Holder" video.
@@rauldragu9447 TOT show his face on the 100k sub videos thats the first and last
This Young Tony
Julian Kandlhofer dammit too late
Some thoughts I had mid way through the video:
Would it be of any use to prototype molds with thinner gauge metal, or even aluminum foil?
Perhaps adding some relief cuts in the blank would remedy the “bunching up” problem
Maybe you could try forming metal preheated in an oven or use annealed stock
I’m just a lowly woodworker, but my engineering degree helps me see the genius in this man. You sir, are inspirational. Also, the way you include your wife gets the approval of my wife, and now she watches with me. Thanks for sharing. My kids will be shown you as an example of how cool it can be to be smart and capable with your hands.
You are what I want to be when I grow up. I'm 24
@@ccriztoff and you sir, are a hater
@@ccriztoff damn u didn’t have to violate him
@@ccriztoff damn what a rude thing to say
Man child
@@ccriztoff if you think your funny Ummm... YOUR NOT
I have a even worse idea:
Full metal crocs.
Weaponized lack of dignity
Yes
👁👄👁
@Levente Horváth just what I think when I saw it.
Born to croc
Cool! Been wearing Bistro line Crocks for over 13 years!!! great stuff!!!! I would definitely want those for work!
Your videos are fantastic, I really appreciate them. Thank you!
I legitimately moved my right leg out of the way when he dropped the weight on his
lmao same
same, it happened to me too many times
I did too! And I'm laying in bed!
@@charles67198 lmaoooo I was gonna say this till I read it lmaoooooo
Same🤣🤣
Die design is a fickle beast. Easily as much art and intuition as science. I must commend you. You have wrapped your head around draw die concepts that take years for some die design engineers to grasp. And you’ve done it with a Chinese press and some scraps of wood!! As far as showing your face on camera...I’d say whatever makes you more comfortable and doesn’t interrupt you workflow too bad.
Genuinely one of the most endearing creators on engineering yt
So I make my own custom bending and forming jigs out of steel for mass production.. this is really exciting seeing how someone else makes their forms.. the more you make these forms it will become second nature where it usually works after the initial idea..
I dreamed about steel toe Crocs since I first started wearing them in the shop. I can't believe I'm not alone. Will definitely buy ones..
They do make croc type shoes with protection. Toffeln EziProtekta comes to mind. Look around in your work shoe stores, you will find them.
What about Birkenstock A 640?
"Metal really likes the shape that it is"
Very inspiring, good for metal
lmao
As a professional UA-cam viewer, I really like how you do the mini-videos at the bottom to show us the minor tasks (like 14:45). You have a very good intuition about video pacing to keep our attention.
Yes my wife and I think you are doing great and enjoy when you show your face to the camera. Thank you for what you are doing
Engineering decision making 101:
Why is the plate 16 gauge? Well, my wife was asleep
That basically men’s decision making 101. :D
Why are we having McDobalds for dinner? Well my wife was asleep.
Why is you daughter eating so much candy? Well my wife was asleep
I come from aircraft engineering so I’m more of an aluminum guy, but we would typically use annealed stock for a formed part with radii that tight, and then use the work hardening itself or tempering to hit specs. I’d reason that you would still run into some issues if you fully annealed the stock at the start just based off the gauge you’re going with, but if you started with an initial rig that is similar to what you have going, I’d say you could take it three quarters the way to your ideal shape and avoid buckling. From there you could trim to your final dimensions, hit it with a quick torch anneal (benefits of it seeing a croc and not an aircraft haha), and then pop it into a final forming block (a registration pattern of some sort would be helpful) that would set your final dimensions and work harden it back to steel toe territory. Would hopefully avoid a lot of springback related calculations, and would mostly just give you an excuse to put a mirror polish on those bad boys!
Anyways, just figured I’d throw my hat into the ring! Who doesn’t love a little armchair manufacturing engineering? 😂 Love the videos!
But for this he would need different equipment right? In order to anneal wouldnt he need some kind of metal oven?
@@One_Shot21 Torch
@@stockphotosguy6037 I feel ya
That was a nice bit of education. Thanks for taking the time to comment.
@@stockphotosguy6037 when you bend or harden metal, you leave a lot of stored stress in the metal. Stored stress makes metal hard, which also makes it difficult to bend. Making the metal really hot, keeping it hot for a while, and then letting it cool really slowly gets rid of the stored stress. With less stress, the metal is easier to bend. The process of heating, holding, and slow cooling metal to remove the stored stresses is called annealing.
There's actually more to it involving the crystal structure of the metal, but that's the easiest explanation for layman's terms.
Didn’t “I did a thing” also make steel toed crocs?
Yes. Very, very, VERY badly compared to this.
@@medicmike2836 the whole point of I did of thing is to do weird things very badly to disappoint viewers
@@medicmike2836 i agree. very badly
@@Ididathing hey I recognize you but I do not know fom where
@@prestonshaw5391 Not really disappoint. Though I did a thing usually doesn't care about the end product, his videos are for the purpose of entertainment(so the end product tends to be bad because that looks funny). Which is totally fine. His focus is just shifted towards entertainment and I have to say that I did find his videos very entertaining.
the indent for the steel wa genious and the massive wood design, it was amasing fit
Just discovered this channel. Love the content and energy.
i know this video is months old and you may not read these, but i appreciate when you look into the camera while explaining something because it seems easier to focus on what you're explaining
I know someone who made steel toed crocs, his name is ‘I did a thing’.
So what you are doing is soft forming.... in a way, just a tip, your "tool" is pt so its harder than your punch, the crop form in other words. Add a 90° bend to the outside of the stock use that bend as a clamping area that will force the material to stretch rather than pull. If the material pulls you'll have some good and some bad parts. Try AMS 5510 around 30 thousands. With my suggested method in combo with your methods you should have a 25-27. Thousands thick steel toe. I did a lot of forming,machining, and sheet metal work but thus I enjoyed the video! One more recommendation is pick 2 different materials. One vastly stronger than the other. I recommend using pressure treated for the punch, and steel for the tool. Ideally heat treat your tool steel to prevent wear and tear
Big science words make me head hurt
Big brain words no fit in penut brain
Who are you friend?
Is my understanding correct in that you want to make the material thinner rather than drawing it in from the sides? I can see that drawing the sheet to be smaller in length would easily make creases.
@@thetedmang Thats @ZiggsEdits !
As someone who left an engineering path to pursue custom fabrication, I really enjoy watching your approach and perspective.
Couple of insights from my experience, in case they might be helpful - MDF to make your bucks. It's much more predictable, leaves a better surface on thin/soft, and just the right amount of conformity on the edge for
this video is great inspiration for me to continue working on my projects!!!
This guy is literally the personification of:
"How old are you? Between 7 and 37"
He is mark zuckerberge
he looks very familiar, i cant say how but he does, also looks late twenties maybe early thirtys
He reminds me of at least 5 different people from college, which I graduated from in 2013. I would say 27-32 is the range.
This is why the subreddit r/13or30 exists.
Looks like tony hawk’s son
I like the no face “ala young tony” style. And also like this old tony videos I watched the whole 24 minute with a smile. Even tho I don’t know why, it’s a asset for a croc for f*ck sake.
Great work
Great attempt.By the way what gauge us the croc sheet ?
Also you can watch the whole thing without it feeling like an hour which means it’s good content.
Have you seen the ToT video where he does show his face? It feels weird after so long not seeing it.
young stalin i see you
the projects dont exist without you soyou are actually the star.
i cant believe no one ever told you to take a torch and HEAT UP THE METAL. makes it waaaaaay more malleable.
I absolutely loved that you interrupted "made of money" with an ad. That's amazing XD
It didn't do it for me, so it must've just been a coincidence lol😂🤣
but I love how he's suddenly wearing expensive gold and diamond jewelry when he says that🤣
Exactly
Lol i checked the comments while the ad played and it's exactly how it happened
They dont decide where the ads go, UA-cam just places them where it wants based on one of their algorithm.
Is no one going to talk about the poptarts just sitting on the table. That's the most genuine part of this whole project.
We had a whole storage room filled with hand made wooden forms for sheetmetal. Made forming complicated parts a whole lot easier and simple, hammer it to form and you're done.
Great video! I think I'm late to suggest, but the tools need a stripper plate. Stripper plates will be connected to the top plate with springs which exert force on the sheet before the top punch makes contact with the sheet. This way the sheet flows uniformly because of the resistance/force exerted by the stripper.
As a professional UA-cam viewer, I really like how you do the mini-videos at the bottom to show us the minor tasks (like 14:45). You have a very good intuition about video pacing to keep our attention.
Mate, we should have a dance off!
How can i be a Proffesional UA-cam viewer?
Professional UA-cam viewer lmao
@@brodyyoung8296 Ahem... Professional UA-cam *Viewer,*
“What are the holes in crocs for?”
“That’s where your dignity leaks out.”
Stuff made here guy: “Oh ya. Watch this”
My mom wants a croc made metal not just the toe
Jacinto Rodriguez i am your mom
@@doctorkocktor1347 i read this in a darth vader voice
I’m not sure of the condition of the sheet metal when you start, but I’m thinking annealing the steel first to soften the alloy to reduce spring back and allow the steel to more easily stretch during forming. If it is too soft for proper foot protection after forming it could be tempered to a spring temper if it has sufficient carbon content.
So very interesting! Great video! while using a press with a die when we make the shape of a fuel tank we spray a little grease on the sheet of metal so the metal don't rankle or tear ...
Hello, i may be a little late on this comment, but on your wooden press, wood is realy good at handelling compression, as long as the compression happends in the dirrection of the grains, think of them like a bundle of matches, if you press down on the tip of a match, it wont brake that easy, but if you press down at the side of a match it snaps. its the same thing with the wood itself.
So if you try to mass produce steel toad crocks in a wooden press, keep that in mind.
this is important
🧠
Being an engineer, I think he knows
Steel toad
Do you think it's possible light travels at different speeds in opposite directions?
ua-cam.com/video/pTn6Ewhb27k/v-deo.html
One suggestion: You could design it so that you purposefully allow crumpling to happen at the back end (the part that you are going to cut off anyway) so that all the pressure will be dissipated to that spot making the parts that matter crumple less.
Shoes were made out of wood before you were born .When in Europe my family went to Holland and got wooden shoes more of a novelty in 1965.
Thanks for sharing this, I really enjoyed watching the iterations you went through. Thanks again much appreciated.
What if something happened to fall and land at the back edge of the steel, could (or would) it fold down into your croc/foot?
How heavy would something have to be for that to happen?
I’m interested because I have a cautionary tale.
I was in a shared art studio with several people working on different metal sculptures and related projects.
Everyone was meant to be wearing steel capped boots (made to the Australian safety standards), but one dude had purchased a cheap pair.
So anyway, he was cutting a big sheet of metal with a gas-axe, had the piece to be removed hanging over the edge of the workbench and….yeah, that large piece of metal (about an inch thick and approx 2foot x 1 foot) it fell down and landed right on the back edge of the steel toe, the steel toe insert bent down and cut into his foot, sliced off 2 toes and almost severed the others. It was a great day for everyone obviously 🙄.
Long story short (er)
Everything was (kinda) okay in the end, lots (and lots) of blood and lots of tools in the studio available for the paramedics to cut off the boot (Gag)
And off to the hospital with toes in a bag that were then put inside another bag filled with ice.
All toes except for one were saved.
Soooo, LESSON LEARNT.
Don’t be a cheapskate with safety gear…just don’t..NO.
Also -
Safety was drastically improved, footwear inspected prior to ANY studio access.
No appropriate footwear, no access.
Apologies for the overshare, but the mention of steel toes, always makes me think about that damn “back edge” and it’s guillotine potential - awesome I know. 🙂🐿
I believe the back edge is reinforced on most steel toes to protect against this problem, I might be wrong though and it might just be my pair.
@@nikkiofthevalley oh for sure, it was really obvious upon inspection (and he admitted to it) that he had purchased basically a fake pair of steel caps. Hence the cautionary tale. It’s frightening to think that people will manufacture fake safety equipment, but given the mark up, not totally surprising either.
Plot twist: He's actually using an aging filter the whole time.
1:00 is his real face and age.
It was uncanny how much that looked like him.
When he did the "Continue in part 2" I quickly went to check if he posted it already.. yeah I got pranked..
same
We all got played
And his wife didnt get pranked this time. Unusual twist.
I cussed him out then apologize
I just checked how much was left of the video, noticed it was a lot and understood it was a joke. Also I'm a self-titled professional UA-cam watcher.
Yeeeeeeeees! I finally found the video where you say what app you use to draw stuff. Man I looked for this a long time.
I really do adore this man's tenacity. However I can't believe there's a human being on this planet so committed to crocs.
"I did a thing" youtube channel did this too
His video was mostly a joke though. Stuff Made Here seems like he'll seriously use his custom Crocks. Considering in other videos you see them on.
@@hunterm.moreno4201 to be fair, im pretty sure IDidAThing uses his steel toe crocks, but these are way higher quality.
But this guy even said he is the first but i did a thing had still done it before weather on not it looks different he still did it
Look at pinned comment
He did it first
I had a lot of similar learnings here when I was doing my first upholstery. Wrapping fabric around a surface curved multiple directions has similar challenges with bending. The solution there was to cut triangles all the way up to the edge of the fabric, which allowed for the material to bend different ways without folding over on itself. I’d be curious if making a similar cutout in the metal blanks would allow the same here, potentially reduce the number of shaping steps required.
I'm sure someone has already mentioned this but metal is easier to form/shape when heated Idk if that's possible with a wooden tool but worth a try.
Great content bro! Keep up the amazing work!
"Does it look like I'm made of money..." cuts to ad lmaoooo I love that😂
That Tormach answers that question with a resounding yes.
It cut to a ad for a bank for me
My ad blocker ruined the joke!
@@thebigtimechannel9927 lol
I dont even have an ad blocker and still didnt get it
I'm here from the future, a year after this video came out, to let you know that wood is probably just as expensive as aluminum currently.
How come?
@@henryg9059 inflation from excess home building
@@christopherbelmonte5145 It's a lot more complicated than that. It would be more accurate to say that wood is expensive because demand went up because of home improvement projects spurred by quarantined people staying home, and lumber mills running under capacity due to a lack of labor
@@isaakwelch3451 I know but this is a UA-cam comments section s it literally does not matter.
@@isaakwelch3451 plus - you repeated what I said using extra words. brevity my friend.
Keep going, you're about to get where you wanna be!
I think it's hilarious that your wife makes all these things and you take the credit for it.
What, where is your evidence?