1 Copper Rose - by Tyler and Mo

My partner (Tyler) and I (Mo) created this project as an assignment for my Intro to Engineering class at National Park College. For this assignment, we were given the freedom to choose any project that aligned with our interests or goals. Since I've always had a passion for flowers and my partner didn't mind, I thought it would be a perfect opportunity to try something new using metal. We wanted to create something ok looking that would allow us to practice our skills in metalworking. That's how we ended up choosing the copper rose as our project.

Creating a copper rose is a beautiful way to immortalize a flower if you're allergic. This tutorial will guide you through the step-by-step process of transforming a simple sheet of copper into a stunning, lifelike rose that can be cherished for years to come. Whether you're looking to make a unique gift, a decorative piece for your home, or simply want to explore the world of metalworking, this project is perfect for both beginners and experienced crafters. With just a few tools and some creativity, you’ll learn how to shape, bend, and assemble copper into a rose that captures the essence of this timeless flower. Let’s get started on this artistic journey!

Before we begin, let's quickly review the Eight-Step Engineering Process that we followed to design and create this project:

1. Identify the problem
2. The first step is to understand the problem you're trying to solve or the goal you're aiming for. In this case, our goal was to create a lifelike copper rose that could be a beautiful, lasting tribute to a real flower.
3. Research and Gather Information
4. Next, we did some research on metalworking techniques and rose anatomy to make sure we understood how to replicate the shape and appearance of a rose in metal. We also looked into the best type of copper and tools to use
5. Generate Possible Solutions
6. With all the information in hand, we brainstormed different ways to create the role. We considered various approaches to bending the copper, creating petals, and adding the stem, before deciding on a more traditional crafting technique of cutting, shaping, and soldering.
7. Select the Best Solution
8. After evaluating the options, we chose to create the rose by carefully cutting and shaping copper sheets for the metals, putting a hole in the middle, and then using a rod to stack them on top of each other with hex nuts in between to support the option. While we did not have a soldering machine on hand, the solution we selected would be both beautiful and structurally sound.
9. Create a Prototype
10. We created the first copper rose by sketching out the general shape, cutting the copper petals, and stacking them together. This first attempt helped us work out the kinks, particularly in how to shape the petals property and how to make sure the flower didn't collapse under its own weight.
11. Test and Evaluate
12. After finishing the prototype, We tested its sturdiness and visual appeal. We also checked the spacing between the petals and the stem to ensure that they were secure. The initial design worked well, but we made some tweaks to improve the overall appeal.
13. Improve and Refine
14. Based on the test, we refined the design by adjusting the size of the petals and positioning them with a hex nut between each petal for better aesthetic flow. We also sanded down the petals to enhance the copper's look.
15. Communicate the Results
16. Finally, we documented the entire process, from concept to completion, to share with others who might be interested in crafting their own copper rose. This step helps in both personal reflection and providing a clear guide for others to follow.

Side note: the pictures below are worked without a soldering iron or heat source. Just a pair of pliers and some grip strength! Do what is easier for you!

Tools:

1. 6in diagonal cutting pliers - will be used to cut the copper. There are many ways but everyone usually has a pair of these.
2. Soldering iron and solder (optional)
3. A heat source for patina (optional. for finishing)
4. Sandpaper or a metal file for smoothing edges (optional)

Materials:

1. Stencil of flower petals - will make it a heck of a lot easier than free handing petals. Will leave the stencil below that I'm using. (I found it online and could not find the artist).
2. Copper core wire 20 gauge - will be wrapped around the steel rods while not necessary I want the whole thing to look like copper.
3. Copper Sheets 0.25" width - I have found that I like K & S Precision Metals which can be found at Hobby Lobby.
4. 5mm x 300 mm 304 stainless steel fully threaded studs rods w thread hex nuts - You can choose whatever type of metal you want for the stem but I am choosing steel because it is what I have laying around.

Now go forth and gather the tools you will use to the copper rose

Tools:

1. 6in diagonal cutting pliers - will be used to cut the copper. There are many ways but everyone usually has a pair of these.
2. Aviation Snips - These will help the cutting process if you struggle to cut the copper with the diagonal cutting pliers
3. Pliers - These will help you manipulate the copper once its cut to bend it to the correct shape you desire
4. Drill - This will help you drill a hole in the middle of the pedal so you have a spot to put the steel rod if you are not soldering
5. Sandpaper (optional) - The sandpaper is used to sand down the edges of the copper so the edge isn't as sharp

Now that you have gathered up all the materials and tools that you will need for this project, you'll need to get started making all your marks and measurements to keep the waste of materials to a minimum.

First, you'll need to either print out or hand draw your outline for the pedals on a piece of paper. The design is optional so it's up to you how you want your pedals to look. Once you have your pedals to your desired liking you'll need to cut them out from the paper so you have singular pedals.

Second, once all the pedals have been prepped for the project you'll need to prep the copper plates by taking them out of the wrapper or separating the copper sheets to where the sheets are spread out by themselves. Now that you've got that done you need to grab your tape and your paper outlines of the pedals and apply them to the copper and spread them out where they are not touching. After you've completed that step you'll need to take that tape and apply that to the pedal outlines to make sure they stay on the copper sheet when your cutting it.

This step is as simple as the three letter word we used for the title. So now that you have the copper sheets prepped, all you have to do if follow the outline of the pedals that are taped down and use your cutting tool to cut them out into singular pieces. Whether you use diagonal cutting pliers or aviation snips use safety precautions by wearing safety goggles/glasses and gloves to prevent injury in this activity.

So at this point your very close to finishing the project. This step is just assembling the flower, but this step is not as easy as it seems. First you need to grab your steel rod and also one of your hex nuts and thread it onto your rod. This will be your bottom nut so thread it on accordingly. After this step is complete you need to grab your pedals and slide your first one down to where it sits on top of your bottom hex nut. Then take your next pedal and repeat the same process but align it so that the pedals cover the cuts of the last pedal. After you have put all your pedals onto your steel rod, your last step is to grab your last hex nut and tighten it down onto the pedals to secure the pedals on the rod and make sure they go nowhere and stay in place. But not to tight because you might damage the copper.

(Optional) We used copper wiring to wrap around our steel rod to give the silver rod the copper look just like the pedals.

This is the very last step in the project but while this is probably the most tedious part of it, it is always the most fun. First you need to get your pliers so you can use to shape the pedals. The second step and final step is the beginning of the tedious part, you need to start by shaping the very first pedal at the top of the stack. Bend them upwards but shape them in the way that you think makes them look the best and express some of your own creativity into the pedals and the shape of your very own rose. But one thing to remember in shaping the rose, if your having trouble shaping them be careful and try not to break the copper pedal.

(Optional) Another thing you can do to your pedals is once you've bent them upwards you can bend the very top of them outwards to create more of a creativity aspect.

Whether you’re a beginner or an experienced crafter, making a copper rose is a rewarding project that combines artistic design with metalworking skills. Through this assignment, we were able to apply the eight-step engineering process to create a beautiful, durable piece that’s as functional as it is decorative. Not only did we get to sorta experiment with metalworking, but we also created something that we can cherish for years to come. We hope this tutorial inspires you to create your own copper rose or try out new metalworking projects!