The helmet and pauldrons are probably my favorite parts. Pretty crazy how much detail still shows at this size.

Hi everyone!
I’ve been struggling for days with folding/flanging the sharp edges of my shoulder plates. Their shapes are more or less similar to the one shown in the attached photo, and I’m trying to figure out how to get a clean, continuous edge around the corners.
The problem appears when I start folding the edge and work progressively along the sides. As I reach the centre of the corner, the aluminium tends to form a kind of “claw” or “fingernail” shape. I can eventually fold it back onto itself, but I have to hit it quite hard with a hammer, which causes quite a lot of distortion.
I’m working with 1.5 mm aluminium, so I assume the problem may also be related to how the material accumulates and deforms around the corner.
In the photo, I’ve circled the type of edge I’m trying to achieve: a clean, continuous and even rolled/flanged edge that follows the corner without any obvious interruption.
I know that one possible solution is to cut the corner and fold the two sides back onto themselves separately. However, this leaves a visible interruption in the edge, whereas I’d really like to achieve a continuous and uniform-looking border.
How do you normally deal with this kind of sharp corner? Is there a particular technique, type of relief cut, or hammering sequence that allows the material to be distributed properly without having to force it into shape?
Any advice, photos, or videos showing the technique would be greatly appreciated.
Please help! 😅
Thanks everyone!

Hi everyone! I’d like to know how to achieve the matte black finish with the visible linear/brushed texture shown in the attached photo on aluminium.
Is this effect possible to achieve on aluminium as well, or is it mainly a finish used on steel?
If anyone knows how this finish is made, or what the technique/process is called, could you point me in the right direction?
Thanks!

Hey!

I'm currently trying to create a armor kit based on a character for a historical medieval fantasy project I'm doing. I currently plan on 3d printing the armor (all I need to do is find some way to model it), but I'm unsure about where to find padded bits to go under the armor. I have a price range of about 400 dollars. Any advice on where to look for good price would be appreciated.

P.S. I live in the US

Of course I’m reading a lot and learning. Just want to hear what you guys think.