Quick Answer
To shape a bangle with crisp corners, use a hexagonal bangle forming mandrel: secure the mandrel, anneal your wire, hammer it around the former, and check the size as you go.
Why a Hexagonal Mandrel?
A round mandrel will round off the corners of a hexagonal bangle. A hexagonal former keeps six flat faces, so the flats stay flat and the angles stay crisp from first blow to last.
The smooth-sanded hardwood surface won't mar soft metals like silver, copper, or brass, so you can hammer directly on the mandrel without worrying about tool marks.
Step-by-Step Bangle Forming
- Secure the mandrel: Clamp the mandrel firmly to your bench or hold it in a bench vice. It must not move while you hammer, or the bangle will distort. Check that the mandrel is rock-solid before starting.
- Prepare your wire: Annealing makes the metal easier to shape and reduces the risk of cracking. Heat the wire to a dull red, quench, and pickle if needed. Don't skip annealing on thick or hard wire.
- Start at the middle: Place the annealed wire against the mandrel at its midpoint. Hammer gently from the centre outward, working each side alternately to keep the curve even. Work symmetrically to avoid a lopsided shape.
- Check the size: Use a ring gauge or measure the inner diameter with callipers. The bangle should be slightly larger than your target size to allow for spring-back. Remember that metal springs back a little after hammering.
- Finish the ends: If your bangle has open ends, file and shape them before final hammering. For a closed bangle, solder the joint before shaping. File ends before the final shaping pass.
- Final hammering: Once the shape and size are correct, go over the bangle with your planishing hammer to even out the surface. Work from the centre outward, overlapping each blow. Check for flat spots or uneven corners after each pass.
Tools That Help
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Bangle Forming Mandrel — Hexagonal Wood, 14 Inch, Hammering & Shaping Tool: This 14-inch hexagonal mandrel is turned from smooth-sanded hardwood and provides six flat faces for hammer forming. The flat faces preserve the corners of hexagonal bangles, and the smooth surface protects soft metals from dents during hammering.
Bangle Forming Mandrel — Hexagonal Wood, 14 Inch, Hammering & Shaping Tool