Cutting & Assembly

How to bend and cut photo-etch parts

Thin brass parts crease, snap or vanish. A few small habits make photo-etch much easier to handle.

Quick answer

Cut photo-etch (PE) parts from the fret with a sharp blade on a hard, flat surface, leaving a small stub, then file the stub flush. Bend along the etched fold line using a PE bending tool or flat pliers, with the fold line at the edge of the jaw, and lift slowly. Avoid re-bending the same fold, because thin brass work-hardens and can snap. Glue with a tiny amount of CA, and hold small parts with a suction pen or reverse tweezers.

TimeRescue: 20-40 minutes per sheet. Prevention: setup before cutting.
DifficultyIntermediate

Safety first

Wear safety glasses; PE parts and cut stubs can fly.
Cut away from your fingers with a sharp blade.
CA glue bonds skin in seconds; ventilate.

Is this your problem?

The fold is soft, rounded or in the wrong placeThe part was not aligned at the edge of the bender: realign and use a bending tool. This page.
The part has a ridge or stub after cuttingLeftover gate: file or sand it flush.
The part keeps pinging away and getting lostSee Tiny parts flying off tweezers or getting lost.
Glue is smeared or white around the PE partSee Super glue white residue.
The PE part will not stay flat on the modelBurnish it flat first and use a small amount of gel CA or epoxy.

You'll see

A fold that is not crisp or not straight, a part that bent in the wrong place, a stub left on the edge, or a part that tore or snapped. Tiny parts also fly off tools and disappear.

Likely causes

Bending with fingers or ordinary tweezersWithout a straight edge to fold against, the metal curves instead of creasing at the etched line.
Fold line not alignedIf the fold line is not exactly at the edge of the jaw or bender, the bend drifts away from the etch.
Blunt blade or bad surfaceA dull blade crushes the gate instead of cutting it, and a soft mat dents the brass.
Over-working the metalRepeated bending stiffens thin brass until it cracks.
Too much glueExcess CA flows over detail and ruins the fold or the surface.

What you need

PE bending tool and/or flat-nose PE pliers
New hobby knife blade or fine cutters
Hard, flat cutting mat
Fine file or sanding stick
CA glue (gel) or PE-suitable glue
Suction pen, reverse tweezers or locking tweezers
Magnifier

How to fix it

Work on a hard, flat surface so the part does not dent. Have a tray or bag nearby for lost parts.
Check the instructions to see which side of the fret faces up and which way each fold goes.
Cut each part from the fret with a sharp blade or fine cutters, leaving a small stub on the part.
File or sand the stub flush with the edge. Support the part so it does not bend.
Clamp the part in the bender with the fold line exactly at the edge, then lift the part upwards in one smooth motion.
For small folds, use flat-nose PE pliers with the fold line at the jaw edge.
Test-fit before gluing. Apply a tiny drop of CA or gel CA with a pin or applicator, keeping glue off the detail.
Hold the part with a suction pen or reverse tweezers while the glue sets.

What to avoid

Bending and un-bending the same fold.
Cutting on a soft mat that dents the metal.
Flooding glue over the detail.

Common wrong fixes

Using ordinary pliers with serrated jaws, which marks the metal.
Cutting all parts from the fret at once so they cannot be found.

Not worth fixing, or time to ask us

If you are working with very fine railway or ship PE and are unsure how to hold it, ask us before cutting. We can suggest a handling method.

Send us a photo

By situation or hobby

Brass PE

Softer and bends more easily, but can work-harden if bent back and forth.

Stainless PE

Stiffer and springier; may need a sharper fold and a firmer bender.

Railway PE (fine parts)

Use gentle pressure and pre-curve long parts over a round rod before folding.

Curved parts

Roll the part over a round rod or brush handle rather than creasing.

Already ruined?

A slightly bent fold can often be gently straightened and refolded once, but not repeatedly. A cracked or snapped part cannot be restored by bending; join it with a small amount of CA, or replace it if the fret has a spare. A part lost in carpet may be found with a magnet or a low-angle flashlight.

Next time

Cut parts from the fret one at a time.
Fold once, in the right direction, with the fold line at the tool edge.
Use a bending tool for any long fold.
File stubs flush before gluing.
Do not re-bend a fold once it has been made.

Frequently asked questions

How do I bend photo etch?

Clamp it with the etched fold line exactly at the edge of the jaw or tool, then lift the part slowly to fold.

Do I need a photo-etch bender?

Not essential, but it gives straighter, crisper folds than tweezers, especially for long folds.

How do I cut photo-etch parts off the fret?

Use a sharp blade or fine cutters on a hard surface, leave a tiny stub and file it flush.

What glue should I use on photo etch?

A small amount of CA glue is common; gel CA is easier to control. Use very little to avoid flooding detail.

Why did my photo-etch part break?

It was probably bent back and forth. Thin brass work-hardens and snaps after repeated bending.

Jargon explained

Fret: The thin metal sheet that PE parts are etched onto.
Photo-etch (PE): Thin metal parts made by etching a design in brass or steel.
Work-hardening: Metal getting stiffer and more brittle when bent repeatedly.

Tools that can help

DSPIAE Square Photo-Etch Bending Tool $66.90
Why it helps: A bending tool with several surfaces for turning flat PE parts into three-dimensional shapes without damaging them.

How to use it
Clamp the part with the fold line at the edge, then lift and fold.
Mo Shi Tools Flat Nose PE Bending Pliers $22.95
Why it helps: Flat nose pliers with smooth, hardened jaws for bending photo-etched brass and rod.

How to use it
Fold small parts that do not fit the bender.
Glass Cutting Mat $39.99
Why it helps: A hard cutting mat made for tasks such as cutting PE parts.

How to use it
Cut parts from the fret on it so the brass is not dented.
Manual Suction Pen $14.95
Why it helps: Holds small styrene plates and tiny flat PE parts that tweezers cannot grip; suitable for small, light parts only.

How to use it
Place tiny flat parts without squeezing them.