EnglishViews: 222 Author: Robert Publish Time: 2025-03-24 Origin: Site
Content Menu
● Preparing the Aluminum Honeycomb Pen Blank
>> Preparing the Tubes and Blank
>> Sanding
>> Polishing
>> Buffing
● Assembly
>> 1. What is an aluminum honeycomb pen blank?
>> 2. What tools do I need to turn an aluminum honeycomb pen blank?
>> 3. How do I prevent the aluminum honeycomb from overheating during turning?
>> 4. What is the best way to finish an aluminum honeycomb pen blank?
>> 5. How do I assemble the pen components after turning?
Turning an aluminum honeycomb pen blank into a beautiful, finished pen is a rewarding project that combines the unique aesthetic of the honeycomb structure with the functionality of a writing instrument. This comprehensive guide will walk you through each step of the process, from selecting the right materials and preparing the blank to turning, finishing, and assembling your custom pen. Whether you're a seasoned woodturner or a beginner looking for a new challenge, this article will provide you with the knowledge and techniques needed to create a professional-quality aluminum honeycomb pen blank pen.
Before you begin, gather all the necessary materials and tools. Having everything on hand will streamline the process and help ensure a successful outcome.
- Aluminum Honeycomb Pen Blank: These blanks consist of an aluminum honeycomb structure embedded in resin. You can purchase these blanks from various suppliers.
- Pen Turning Lathe: A lathe is essential for rotating the pen blank as you shape it with cutting tools.
- Lathe Tools: You'll need a variety of lathe tools, such as roughing gouges, spindle gouges, and parting tools, to shape the pen blank. High-Speed Steel (HSS) or carbide turning tools are recommended[2].
- Drill Press or Lathe with Drill Chuck: Used for drilling a hole through the center of the blank to accommodate the pen tube[1].
- Drill Bits: Select a drill bit size that matches the outer diameter of the pen tubes you'll be using.
- Pen Tubes: These are the brass tubes that will be glued into the drilled hole in the pen blank, providing structural support and a housing for the pen's internal components.
- Epoxy or Cyanoacrylate (CA) Glue: Use epoxy or CA glue to secure the pen tubes inside the aluminum honeycomb pen blank.
- Barrel Trimmer: This tool ensures that the ends of the pen blank are square and flush with the pen tubes after gluing[1].
- Pen Mandrel: A pen mandrel is a metal rod that fits into the lathe and supports the pen blank during turning.
- Bushings: Bushings are small, precisely sized spacers that fit onto the pen mandrel and help you achieve the correct diameter and shape for the pen.
- Sandpaper: You'll need a range of sandpaper grits, from coarse (e.g., 120 grit) to very fine (e.g., 12000 grit), for sanding the pen blank to a smooth finish[1].
- Finishing Supplies: These may include CA glue, micro mesh, EEE-Ultra Shine turners polish, buffing wheels, and wax[1][2].
- Pen Press: A pen press is used to assemble the pen components into the finished pen.
- Safety Glasses: Always wear safety glasses to protect your eyes from flying debris.
- Dust Mask or Respirator: Protect your lungs from dust and fumes by wearing a dust mask or respirator.
- Paper Towels: Keep paper towels handy for cleaning up spills and wiping away excess glue or finish.
If you're casting your own aluminum honeycomb pen blank, the first step is to cut the aluminum honeycomb to the desired size. A bandsaw works well for this task[3]. Ensure the honeycomb fits perfectly into your silicone mold without pressing against the edges[3].
Prepare your mold to cast the pen blanks. This might involve applying a mold release agent, although some silicone molds don't require it[1].
Mixing the epoxy requires careful consideration of the colors you want to incorporate into the honeycomb. Experiment with different color combinations to achieve the desired aesthetic. When pouring the epoxy, try to create a distinct pattern within the blank[1].
Allow the epoxy to harden completely in a pressure tank to eliminate air bubbles. Once hardened, remove the blank from the silicone mold[1].
After removing the blank from the mold, trim one end to square it off. Then, cut the blank to a length slightly longer than the pen barrel. This ensures accurate drilling[1].
Use pen jaws on the lathe chuck to secure the blank for drilling[1]. This provides stability and accuracy during the drilling process.
Using a drill bit that matches the outer diameter of your pen tubes, drill a hole completely through the center of the blank[1]. Maintain a steady feed rate and back out the drill bit frequently to clear chips and prevent overheating.
Clean the pen tubes with sandpaper or a wire brush to ensure a good bond with the glue. Also, lightly sand the inside of the drilled hole in the aluminum honeycomb pen blank to create a slightly rough surface for better adhesion.
Apply epoxy or CA glue to the pen tubes and the inside of the drilled hole. Insert the tubes into the blank, ensuring they are fully seated[1].
Allow the glue to cure completely according to the manufacturer's instructions. This may take several hours or overnight, depending on the type of glue used.
Use a barrel trimmer to flatten the ends of the blank, removing any excess glue and ensuring the ends are flush with the pen tubes[1].
Mount the pen blank onto the pen mandrel using the appropriate bushings[1]. Ensure the bushings are properly aligned and tightened to prevent vibration during turning.
With the lathe running at a moderate speed, begin shaping the pen blank using your lathe tools[3]. Start with a roughing gouge to remove the bulk of the material, then switch to a spindle gouge for finer shaping. Take light cuts and work your way down to the desired profile. Periodically check the dimensions with calipers to ensure accuracy.
Once the pen is shaped, begin sanding with 120 grit sandpaper to remove tool marks[1]. Dry sand to 320 grit, then wet sand with 400, 600, and 1000 grit sandpaper[1]. Progressively work your way up to finer grits, using water to help clean the paper and achieve a smoother cut.
Apply several coats of Starbond Adhesives Thin CA as a finish[1]. Adding multiple coats will give a deeper, wet look to the finish, enhancing the shine and bringing out the colors of the epoxy.
After applying the finish, wet sand the pen starting at 1500 grit micro mesh, working your way up to 12000 grit[1]. This will create an extremely smooth surface for polishing.
Use EEE-Ultra Shine turners polish to polish the pen barrel until you are satisfied with the shine[1]. This method works well with epoxy and enhances the overall appearance of the pen.
Buff the pen to a mirror-like shine using a PSI 3 Wheel Buffing System[1]. Start with the coarse wheel and work your way to the fine cotton wheel, being careful not to let the wheels grab the end of the blank.
Use a pen press to assemble the pen components. Start by pressing the tip tread into place on the desired end[1]. Then, press the clicking portion of the pen into place, ensuring the plastic end goes into the pen barrel[1].
Insert the pen cartridge into the pen, placing the spring on the tip end of the cartridge[1].
Hold the spring in place and screw on the tip section of the pen. Finally, screw in the click button and test the pen to ensure the mechanism functions correctly[1].
- Avoid Overheating: Aluminum honeycomb can be prone to heat buildup during turning, which can cause the resin to soften or the bond between the aluminum and resin to weaken. Use sharp tools, take light cuts, and avoid excessive pressure to minimize heat generation.
- Use Sharp Tools: Sharp tools are essential for achieving a clean cut and preventing tear-out or chipping. Sharpen your tools frequently to maintain optimal performance.
- Apply CA Glue: Reinforce the joints between the resin and honeycomb by applying thin CA glue[6]. This helps to stabilize the blank and prevent the material from shattering during turning.
- Consider Color Combinations: When casting your own aluminum honeycomb pen blank, experiment with different color combinations to achieve the desired aesthetic[1]. Contrasting colors can create a visually striking effect.
- Proper Bushings: Using the proper bushings for your pen kit is crucial for achieving the correct dimensions and ensuring a proper fit for the pen components[3].
- Light Cuts: When turning the blank, take light cuts to prevent stress on the material and minimize the risk of chip-outs[6].
- Sanding: When sanding, keep the sandpaper moving to avoid causing deep scratches in the blank[3].
- Acetone: Acetone can dissolve CA glue, so it's useful for cleaning bushings or removing unwanted glue from the pen blank[6].
Turning an aluminum honeycomb pen blank into a finished pen is a detailed process that requires patience, precision, and the right techniques. By following these steps and tips, you can create a unique and professional-quality writing instrument that showcases the beauty and complexity of the aluminum honeycomb pen blank material. Whether you're a hobbyist or a professional woodturner, this guide will provide you with the knowledge and skills to master the art of turning aluminum honeycomb pen blank pens.
An aluminum honeycomb pen blank is a material used for making pens, consisting of an aluminum honeycomb structure embedded in resin. This combination creates a visually striking and unique appearance.
You will need a pen turning lathe, lathe tools (roughing gouge, spindle gouge, parting tool), a drill press or lathe with a drill chuck, drill bits, pen tubes, epoxy or CA glue, a barrel trimmer, a pen mandrel, bushings, sandpaper, and finishing supplies.
To prevent overheating, use sharp tools, take light cuts, and avoid excessive pressure. Overheating can cause the resin to soften or the bond between the aluminum and resin to weaken.
A good finishing process involves applying several coats of thin CA glue, wet sanding with micro mesh, polishing with EEE-Ultra Shine, and buffing to a high shine. This will protect the pen and enhance its appearance[1].
Use a pen press to assemble the pen components. Press the tip tread and clicking mechanism into place, insert the cartridge, and screw on the tip section and click button. Test the pen to ensure it functions correctly[1].
[1] https://jpaynewoodworking.com/making-a-epoxy-aluminium-honeycomb-pen/
[2] https://exoticblanks.com/products/aluminum-honeycomb-pen-blank-black-yellow
[3] https://www.instructables.com/Honeycomb-Epoxy-Pen/
[4] https://www.penturners.org/threads/aluminum-honeycomb-beauty.162564/
[5] https://www.youtube.com/watch?v=PZtSN2iSvj0
[6] https://www.youtube.com/watch?v=FcplhMcdkWA
[7] https://www.penturners.org/threads/honeycomb-pen-blank-problems.116642/
[8] https://www.langevinforest.com/en/4-pc-combo-pack-aluminum-honeycomb-pen-blanks
[9] https://www.youtube.com/watch?v=8iqXKxvoU0c
[10] https://wttech.de/en/product/blank-pen-blank-turning-blank-in-honeycomb-design/
[11] https://www.youtube.com/watch?v=7aMovxbdV0c
[12] https://www.penturners.org/threads/honeycomb-blank-coming-apart.178355/
[13] https://www.penblanks.ca/honeycomb-pen-blanks-hydra
[14] https://www.instagram.com/baxtersboards/reel/DGJHQarBS4W/?api=1%2F
[15] https://www.youtube.com/watch?v=G3cH1T5_AJw
[16] https://www.penturners.org/threads/casting-honeycomb-aluminum.115057/
[17] https://www.youtube.com/watch?v=hIo8s7yvSeU
[18] https://www.youtube.com/watch?v=mUxppSj-lqA
[19] https://www.youtube.com/watch?v=08hkbGcRAxU
[20] https://www.winecountrywoodworks.com/products/aluminum-honeycomb-alumilite-pen-blanks-alumicomb
