Die Manufacture

[Gordon Williamson]

This series of photos showing the manufacture of an award isn't actually 3rd Reich, but Japanese. The procedure is pretty universal however and gives an good basic overview of how the awards were produced. The first shows the pattern maker hand cutting the large (usually at least x4, often x10 ) master of the award which will by scaled down on a pantograph milling machine to actual size in the die insert. Traditional methods here, none of your laser cut dies used today.

The second photo shows the store rooom for these hand cut master patterns ( I suspect at the Osaka Mint)

[Gordon Williamson]

A pantograph milling machine cuts the x10 or whatever pattern, scaled down to 1:1 into a steel block.

[Gordon Williamson]

Here, the award components are being stamped out. Modern presses are often hydraulic as the one shown here. The pressure required of course will vary dependant on the metal. Going by its size this one looks like a 20 / 25 ton press.

Note the die inserts with the shape of the award are cut into circular steel steel. This is then hardened and when in use fits into a recess in a normal mild steel die block.

The second example shown is a 25 ton press but with the pressure produced by a large flywheel on the side of the machine rather than by hydraulics, in the 30s/40s, most presses were flywheel types.

[Gordon Williamson]

Here the stamped out components are being hand finished. Note the initial finishing process is done using a fairly large, coarse file to remove any flashing, then a fine cut jewellers needle fine is used to finish the job

[Gordon Williamson]

Plating bath

[Gordon Williamson]

Enamelling

[Gordon Williamson]

Firing the enamel

[Guest Darrell]

Great pictures and info Gordon.

[Bob Hunter]

Excellent pictures of a the production sequence. Thanks.