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RAPID FREEFORM SHEET METAL FORMING: TECHNOLOGY DEVELOPMENT AND SYSTEM VERIFICATION

Ford Motor Company - Dearborn, MI

An innovative, programmable metal forming tool capable of simultaneously indenting metal sheets from both sides will be developed. It eliminates the need for hundreds of fixed-shape forming dies typically required as part of the prototyping process in automotive and aerospace design. The new technology is projected to reduce material scrap by 70%, energy consumption by 70%, and production costs by up to 90%.