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5 Innovations to Watch Out in Metal Shaping Process

a man doing a metalwork

Photo by Tima Miroshnichenko on Pexels.com

Metal finishing is on the rise, and thus, the innovation process is continuous. You might think that metal shaping is not a very needy process but when it comes to the business with manufacturing requirements, a better innovation is always required with metal shaping. 

While the industry has only scratched the surface of innovation, there is a lot of work remaining. However, with the growing demand for manufacturers, finishing needs to be top-notch. 

As a result, the metal finishing industry has gone to $95.2 billion in 2020 and is only growing further. If you look at 2024, there is a lot of innovation added to the shaping process. 

These innovations not only improve the quality of finished products but also reduce production costs and energy consumption. 

Check these most effective innovation steps.  

1. Additive Manufacturing (3D Printing) for Metals

Additive manufacturing, or 3D printing, has been a game-changer in various industries, and its application in metal shaping is no exception. Traditionally, metal shaping involved subtractive processes like cutting, milling, and machining, which often resulted in significant material waste. 

In contrast, additive manufacturing builds components layer by layer using metal powders, reducing waste and allowing for the creation of complex geometries that would be difficult or impossible to achieve with traditional methods. 

Laser-based powder bed fusion (PBF) and directed energy deposition (DED) are two of the most common techniques used in metal 3D printing. These methods allow manufacturers to create lightweight, durable parts with high precision. Additive manufacturing also enables rapid prototyping, significantly reducing the time required to move from design to production. As technology advances, it is becoming more accessible for small and medium-sized manufacturers, making it a trend to watch closely in the coming years.

Also, metal injection molding is a new and reliable process to give a complex shape to metal components.

2. High-Speed Incremental Forming (HSIF)

Incremental sheet forming (ISF) has been around for a while, but recent innovations have led to the development of high-speed incremental forming (HSIF), a more efficient and scalable version of the process. HSIF involves the gradual deformation of a metal sheet using a tool that follows a programmed path, creating complex shapes without the need for expensive dies or molds.

What sets HSIF apart from traditional metal shaping methods is its flexibility. Unlike stamping or deep drawing, which require custom tools for each new part, HSIF can quickly adapt to different designs, making it ideal for small-batch production and rapid prototyping. The high-speed variant of this technology further reduces production times, making it a cost-effective solution for industries that require high customization and agility in production.

 3. Laser-Assisted Metal Forming

Laser-assisted metal forming combines traditional forming techniques with the precision and efficiency of laser technology. In this process, a laser is used to heat the metal locally, softening it and making it easier to shape with less force. This method reduces wear on tools, improves material flow, and allows for the forming of hard-to-shape metals such as titanium or high-strength steels.

One of the key advantages of laser-assisted forming is that it allows for greater control over the forming process, resulting in more accurate and consistent shapes. Additionally, by reducing the forces required for shaping, the process extends the lifespan of forming tools and minimizes the risk of defects like cracks or wrinkles in the finished product. This innovation is particularly beneficial for industries that rely on high-strength materials, such as aerospace and automotive manufacturing.

4. Magnetic Pulse Forming (MPF)

Magnetic pulse forming (MPF) is a high-speed forming process that uses powerful electromagnetic pulses to shape metal parts without direct contact. A coil generates a magnetic field, which induces a strong current in the metal, producing a force that rapidly deforms the material into the desired shape. The speed of this process—often completed in milliseconds—enables manufacturers to create intricate shapes with high precision.

MPF is particularly advantageous for shaping non-ferrous metals such as aluminum and copper, which are commonly used in lightweight applications. It can also be used to join different metals, such as aluminum and steel, which are difficult to weld using traditional methods. MPF reduces the need for mechanical contact during the shaping process, minimizing wear on tools and extending the life of production equipment. This makes it an energy-efficient and sustainable option for metal forming in industries focused on lightweight construction and sustainability.

5. Hydroforming with Advanced Materials

Hydroforming is a well-established technique for shaping metals, but recent innovations in materials and process control have made it even more versatile. In hydroforming, a metal sheet or tube is shaped by applying high-pressure hydraulic fluid to press the material into a die. This method is highly effective for creating complex, lightweight parts with uniform thickness.

Advanced hydroforming techniques enable manufacturers to produce stronger, lighter components with minimal waste. This innovation not only boosts efficiency but also aligns with the growing trend toward sustainability and the reduction of material consumption in the manufacturing process.

Innovations are effective only when it saves your time and money. Try and apply these innovative approaches in your business to know which is effective for your process.

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