In Nov I created an 8×12″ T Rex skull copper plate to see what level of detail I could achieve and how much my cutting machine adds to the process.
In 2020 I enjoyed making multiple 8×12″ copper maps of Newfoundland & Labrador by hand, but I was limited in what I could do. I had recently decided to purchase a cutting machine to both be able to achieve finer detail in any stencil I make, and to increase production. The cutter has been working great for map outlines, but I need to see what it can really do. I have been working on a detailed design of a T Rex skull from a reference photo and I want to try and make a copper plate with it.
I got ambitious and started out with a 5-tone design, including the background, but decided to reduce it to 4 colours. I had to convert my multi-coloured design into a monochromatic image for the cutting machine software to trace it properly. I will track my time to gauge how much work a highly detailed copper plate like this will take.
There are so many small bits of the vinyl stencil that fell off during the cut that I’ve decided not to sweat it. They are all tiny holes, so I don’t mind that they will end up painted black on the plate. I carry on with applying the transfer tape to move the stencil onto the copper.
The stencil started getting some wrinkles on the end and a bit of the upper brow went over the top edge, but I decided that I would continue anyway. If it was for a client I would cut another stencil and restart to get a better placement, but this prototype is about the proof of concept, not perfection.
The first colour to do will be the black, so I weed out the stencil, apply tape to cover the exposed edges, and spray on 2 thin coats of black paint to ensure good coverage.
Weeding for the black took a long time, but the background went quite a bit faster. The skull has a few pass-through holes in it where the background will be seen.
I put chemicals on the background to get a blue patina then put the plate in the container to react. Blue forms on top of the copper and can flake away easily. After the plate came out, I washed it, dried it, brushed away the loose flakes, and sealed with clear coat.
I repeated the process of weeding and adding chemicals for the brown colour, then sealed the plate in the chamber to react overnight. I take out the plate to wash, dry, and seal it. Finally, bare copper just needs weeding and a clear coat.
Overall, I am pleased with the result of this prototype. The 8×12″ T Rex skull looks good and I learned a lot as I worked though the process in making it. The total hands-on working time to make this plate, from pile of materials to finished plate, was about six and a half hours. I did not keep track of the amount of time I spent on the computer because I was teaching myself how to use the software by making the design from a reference photo. I think I’ll hold onto this plate and have it on display as a demo piece when I get a table at a farmer’s market or craft fair.