Dial

The dial creation process was difficult and had many dead ends. First, there are a number of components/layers:

  • base dial
  • textures
  • printing or engraving
  • Indices and logo
Dial made of 3 layers with different textures

I knew I wanted to have a recessed seconds sub-dial and a recessed central area, each with a different texture. I will start by describing my first attempt using 3D printing and pad printing, then will show another version using a CNC machine, engraving and engraver’s wax.

The dimensions below are those needed for a basic dial for an ETA 6498 movement or any of its clones, which is what I used for my sport watches. All units are in mm.

Dimensions in mm for a basic dial for the ETA 6498

The first task was to create the base layer, which I first tried doing by gluing 3 0.3mm sheets of metal together. The problem with that system was the lack of precision. I then tried to have 3 different textures on a single flat dial, but again it was difficult to achieve the right level of precision. In the end, I designed the base dial in a modelling software and had it 3D printed in brass, plated brass and silver.

Dial in silver, brass, and brass with black and white rhodium plating

The next step was to add textures to the different parts of the dial. For that I used sticky paper that I cut to the correct size to create masks so that I could protect parts of the dial while texturing others.

Using sticky paper masks to protect parts of the dial

The sunray finish was produced with an abrasive wheel on a rotary tool with the dial on a turning table. The frosted finish at the centre of the dial was obtained with a 40mm texturing wheel with 0.30mm filaments. Finally the satin finish of the external ring was done with a 400 grit abrasive mesh on a rotary tool.

Sunray finishing

The following step was to print the design I had prepared as a vector image. I tried using film-free decal paper, but it was impossible to get the right level of precision and the process involves heating the dials, which gave them a yellow tinge. I therefore opted to had them professionally pad printed.

Pad printed dial

Finally, I created the indices and logo with my modelling software and had them 3D printed, after which I finished them manually.

Dial with texturing, printing and applied indices and logo

For another version, I used my CNC machine to cut the dial, subdials, and engrave all the elements that would otherwise have to be printed.

Dial being produced on my Carbide 3D Nomad 3 CNC router

For the different textures, I used thick sticky paper to protect the parts that should not be textured and used my Dremel with either a texturing wheel or abrasive wheel to create different textures.

Dial with sticky paper protecting some areas and the rest left exposed to be textured with the texturing wheel using my Dremel.

For the small seconds, instead of a sunray finish, I used a circular graining pattern.

I stuck some adhesive lapping paper to the felt pad on my Dremel and used the press to improve the accuracy.
This is the dial before adding the engraver’s wax. The small seconds sub-dial has circular graining, the central part of the dial is frosted and the outside track is straight grained. The logo was produced separately and glued into a recess.

You can see below the material I used to apply the engraver’s wax: a Dremel torch and a bar of wax. I held the dial with pliers while heating it, then melted some wax on and immediately removed the surplus with some kitchen paper. Once I had finished, I used ear cleaning buds dipped in acetone to remove any wax that wasn’t in a recess (that process is more art than science).

This is what I used to add the engraver’s wax: Dremel torch, bar of engraver’s wax.
2 versions of the dial, both using engraving and engraver’s wax (no pad printing). The left version has applied indices. Both dials are made of silver with the logo made of brass.