This is not an easy thing to do. The aluminum is soft enough it will warp, and it is tough, but not impossible to get it back flat again. Big rolls- you will need 4' wide rolls, that will roll 1/8", and run it back and forth a bunch of times, and as long as you havent overdone it, and created some bowls, that will take it back pretty flat. My advice, though, is not to try to texture aluminum sheet yourself. Consider a few other directions-
1- buy pre textured sheet. The big dogs in this field is Rigidized, in Buffalo New York- they make pretextured sheet in a wide range of patterns, in a variety of metals. Their main thing is stainless, which is better than aluminum for this anyway- it takes a texture better, its harder so it will wear better, its thinner, lighter, tougher, and resists oxidisation better too. Aluminum will oxidise, and get white junk on it, unless you clear coat. The stainless will just sit there. However, if you insist, I am pretty sure Rigidized will roll aluminum for you.
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you must texture aluminum, the way it is done is with textured rolls- 4' wide, probably a minimum of 4" in diameter, with the texture ground or pounded into it. Then the aluminum is fed thru, powered, of course, minimum of maybe 3hp to do this. 1 shot, the whole piece is textured. This is how rigidized does it. I realize, this is not cheap or easy- but what you wanna do isnt common, and there is a reason for it.
3-Other metals are gonna hand texture a whole lot better than aluminum. I have been texturing a lot of stainless lately- I use needle scalers, with a variety of modified needle shapes, and air chisels with modified tips. Stainless is hard enough it doesnt wanna bowl near as much. Of course, we still have to run it back and forth thru the rolls a few times, flipping it, to get it flat again. But I have been having good success with 1/8" 304 sheet this way.
4- I am not sure how your etching is gonna work- thats something I dont know much about. But I have also done texturing of surfaces like this with sandblasting- you can get this cool adhesive backed rubber sheet, in rolls. You cut out your pattern with an exacto knife, and peel off the negative parts, then blast. Works pretty well, with the time spent blasting controlling the depth of the texture. You could buy the rubber yourself, then pay someone who is setup to blast. The rubber stuff can be gotten at big signmaking supply companies- they use it to make sandblasted wood and stone signs. TP has it too.
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