Annealing: Annealing is the process of reducing stress within the metal’s structure by heating it to a prescribed temperature. Stress in the metal is caused by working the metal with tools by texturing, forming, etc. In a work-hardened state, metal is difficult to form and can crack. It is often necessary to anneal metal several times during the forming process, especially when forming in the hydraulic press. Do NOT anneal your metal before using pancake dies. Anneal your metal for use with impression dies.

Blanking: Blanking refers to the process of using simple steel dies to rapidly cut out different shapes from sheet metal. 

Bottle Jack: A bottle jack is mounted vertically beneath a load that is to be lifted in a hydraulic press. It is a closed system that compresses fluid to transfer pressure through the tool and raise and lower the platen. In the manual Potter USA press, it is what raises and lowers the lower platen of the press and what exerts pressure on dies and other forming tools. The ram is raised by manually pumping the handle, and pressure is released by turning the release valve on the bottle jack. Potter USA sells a 20-ton bottle jack, which is suitable for all the press tools we sell.

Burrs: Burrs are raised, sharp edges left on the edges of metal after cutting or different machining operations. Burrs will need to be removed from cut metal blanks. Potter USA’s pancake dies are designed to work with a wide range of metal gauges (16-22g). Because of this versatile design feature (hand-cut pancake dies are specific to one gauge of metal), there will be a minimal burr on your cut blanks. 

Dead Soft: Dead-soft metal is in an annealed state, and it is very malleable and easy to work with. It accepts textures, hammering, and shaping with ease. As it is worked (by shaping, bending, etc.) the metal will gradually work-harden. Dead-soft metal is an excellent choice for use with impression dies. Do NOT use dead-soft metal with pancake dies. When you purchase dead-soft metal from a manufacturer, it will not be as soft as when you anneal metal yourself.

Die-struck vs. cast: Jewelry components that have been die struck are extremely dense, durable, and lack the porosity that is common in cast components. Die-striking is a form of forging, where softer metal is formed under intense pressure to conform to the shape of the die. 

Durometer: Durometer measurements indicate the hardness of urethane. The most commonly used durometer hardnesses in jewelry-making are 60D to 95D. A 60D urethane is the softest and is useful in creating volume. A 95D urethane is the hardest and tends to give more detail but less volume.

Electric Pump: An optional upgrade, Potter USA’s 20-ton electric pump and motor allow you to use our tooling without having to manually pump a bottle jack. The pump sits at the bottom of the press and performs the same tasks as a bottle jack. The electric motor sits to the side of the press and includes an on/off switch and handle that raises and lowers the lower platen of the press. An electric pump/motor is a good option for those with difficulty operating a manual jack, as well as for those who do production work.

Fast Stamping System (FSS dies): Potter USA’s Fast Stamping System is a different style of blanking die. Kevin Potter designed this first-of-its-kind tool in 2015 with the goal to bridge the gap between an inexpensive pancake die and a $2000 tool-steel die set, commonly used in industrial die striking. The Fast Stamping System is comprised of a die shoe (includes a die shoe base, a pusher plate, and springs), interchangeable die sets in various shapes and sizes (includes a die set top, bottom, and urethane). The die set is placed onto the pegs of the die shoe base, metal is inserted into the die set, the pusher plate is placed on top of the die set, and then the system is placed into a hydraulic press to cut metal blanks. Metal sheet can be fed into the die, allowing for rapid production of blanks. This new method allows Potter USA to produce a die set for less than $100, making it affordable to artists who need more production capacity than what a pancake die affords them. The FSS (Fast Stamping System) helps speed up small-scale production of metal blanks, as well as accommodates a wider range of metal gauges than pancake dies. And it's able to be re-sharpened, if/when needed! The FSS (Fast Stamping System) is a precision tool and must be treated as such.

Full-hard: Full-hard metal is metal that has been significantly work hardened. It is difficult to form but holds its shape well and is a good choice for items like clasps and hinges. The harder the metal, the more spring it will have. Use only full-hard metal with pancake dies.

Gauge: Gauge refers to the thickness of metal. 

·      Pancake dies: ONLY use 16-22 gauge full-hard metal. Do not anneal, and do not assume your metal is full-hard from the manufacturer.

·      Impression dies: The gauge is determined by personal choice and intended use. Typically, if you’re forming metal sheet in impression dies, you’ll use 22-16 gauge, but that range is not set in stone, as you can also use thicker sheet or ingots to press solid. Experience and practice will dictate what gauge to use with each impression die. 

·      Silhouette dies: Typically, you’ll use 22-18 gauge, but you can use metal outside this range with experimentation and practice, depending on your desired outcome.

Half-hard: Half-hard metal has been partially work-hardened. It’s stiffer than dead-soft metal, and is more difficult to form, hammer, etc. Half-hard metal holds its shape under some stress, will work-harden quickly, and is a good choice for items like ear wires and open jump rings.

Hub: A hub (hob) is a hand-carved or machined block of steel with a raised, 3-dimensional relief design. A hub is the raised (or male) design that is used to make a die. You cannot use hubs to form metal, only dies. Hubs are hardened to withstand being sunk into a softer block of steel to create a die. Master hubs were designed to be struck one or two times to create working dies for stamping manufacturers. At Potter USA, we often must make copies of hubs to ensure the original hub is not broken or destroyed, since the master hubs weren’t designed to be struck repeatedly. By making copies of the master hub, Potter USA ensures that the original art will survive for centuries to come.

Hydraulic Press: A sturdy steel structure in which a manual hydraulic jack or electric pump and motor is used to apply localized pressure on a die or forming tool. 

Impression Die: A die is a block of steel with a negative (female, or debossed) design, used with urethane or lead, into which non-ferrous metals are formed. It is a mirror image of a hub. Potter USA sells impression dies made from antique hubs. In our product listings, we show the hub, since it represents what your stamping will look like after using the impression die you receive. 

Pancake Die Opener: Handheld tool designed and sold by Potter USA for opening pancake dies after use to help aid in inserting metal into the die. It is NOT a tool for removing stuck metal from the die.

Pancake Die: Pancake dies, also called blanking dies, are thin steel dies used for rapidly cutting out shapes from sheet metal. Pancake dies contain a long tab with a design at the end of the tab; the long tab allows the die to be sprung open so that non-ferrous metal can be inserted into the die. Traditionally, pancake dies have been expensive and hand-sawn, with the cutting edge cut to a specific angle to accommodate a specific gauge of metal. Kevin Potter pioneered the affordable, laser-cut pancake die, which has straight cutting edges, but will work with a wide range of metal gauges rather than a single gauge. Potter USA typically has 200-300 designs available at any given time.

Pattern Plate: Potter USA’s pattern plates are 2” x 7” plates of mild steel used for texturing metal with a wide variety of patterns. They are designed for use in a rolling mill but can also be used in a press with more effort. The steel we use will NOT mar or damage the hardened steel rolls of your rolling mill, as it is far softer than case-hardened rolls.

Platen: An integral part of any hydraulic press is the lower platen. This rests on top of the bottle jack or electric pump and is what you place your tooling on to use the press. The upper platen is attached to the top of the frame and is parallel to the lower platen. It’s what your tooling is pressed against. The sizes, shapes, and methods of attaching the upper platen vary.

Pressing “Solid:” Pressing an impression die solid describes the process of using metal thicker than the depth of the die to create a stamping with a flat back. No urethane is used when pressing solid, just metal against the tool-steel pusher. We recommend pressing solid for: rings, shallow designs, shot plates, and other small designs where the added weight won’t be an issue.

Pressing “Hollow:” Pressing an impression die hollow means you use a conforming part (urethane, paper, cardboard, lead, etc.) to form thinner sheet metal into the die. The sheet metal is formed into the impression, and the forming is visible on both the front and back of the stamping. We recommend pressing hollow for: deep designs, earrings, or other designs where excess weight is not desirable, large designs. Traditionally, sheet metal stampings are backed with a second sheet to create a more professional look.

PSI: Pounds per square inch. If you have a press with a gauge, it’s useful to pay attention to this when using silhouette dies if you need to make many of the exact same design that are formed to the exact same depth. A gauge is not necessary, though.

Ram: The central, cylindrical column of a bottle jack that raises and lowers when pumping the handle. Always use spacers to avoid over-extending the ram. Ideally, your ram shouldn’t have to be raised more than an inch or so. Add spacers as needed based on the tools/dies you’re using.

Silhouette Die: Silhouette dies are used to form or “puff” metal sheet. Used in conjunction with a urethane puck or sheet. Silhouette dies are flat pieces of steel with cut-out design in the center. They work best in a contained urethane system. You can texture your metal, anneal it, and form it with a silhouette die without losing surface detail.

Spacer: Aluminum spacers reduce the distance the hydraulic ram or pump must travel when used in a hydraulic press. You MUST use as many spacers as possible with all tools to avoid overextending and damaging your jack. We recommend having 4-5 spacers on hand. Do NOT use steel, wood, or acrylic spacers in your press.

Stroke: The total distance the ram can travel from full extension to full retraction.

Tonnage: The maximum amount of force that the press can apply.

Tool Steel Pusher: This 2” diameter tool is magnetized and has a tool-steel face for focusing the pressure on a small surface area. We strongly recommend this accessory for use with impression dies. Do not use the pusher with FSS dies or pancake dies.

Urethane: Urethane is a rubber-like material that flows, rather than compresses, under pressure. It’s used in conjunction with impression dies and silhouette dies. It forms metal gently and evenly, and is available in a range of hardnesses, called durometers.

Work-Hardening: Work-hardening occurs when metal is formed, bent, or twisted. Though it varies by metal type, the metal becomes brittle and difficult to work once it has been sufficiently deformed. Annealing allows the internal structure of the metal to recrystallize and restores malleability.