Steve B wrote:
I am going to do some decorative work with thin copper sheeting. When you
get into the really thin stuff, like about as thick as matchbook paper, is
there an easy way to accurately cut it? The pieces would be cut at right
angles. I know I can use snips, but that leaves a slight ridge, and I never
can get a really straight cut. On some decorative items, I will just have
to use snips of various sorts until I get the right combination.
I have a technique I use for cutting thin copper sheet that
is laminated to PC board materials. I take a #11 Xacto
blade that has been well used, and swipe the point across
a bench stone. It makes it like a micro chisel, although
not as acute an angle. This would make the chisel as
wide as the thickness of the blade, maybe .020" (1/2 mm).

I put a ruler down as a guide and hold the Xacto knife
with a grip like a fist. Then I put the blade against the
material and pull it toward me. I can usually cut through
the .0015" (one ounce) copper on a PCB on the 2nd stroke.

You wouldn't want to use this method except on very thin
copper, and then it might buckle if it wasn't attached to
something. Holding the part you want under the steel ruler
might save the part, though.

This does leave a slight ridge, but you can easily slice
that off with a fresh Xacto knife.

Jon