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Automating an Incremental Forming Machine

Incremental forming is a type of manufacturing in which a sheet of metal is forced into a given shape via small deformations. This is good for rapid prototyping and low-volume production. Some components that can be incrementally formed include automotive body panels, skull plates for cranial repair, and aerospace parts. The Ford Freeform Fabrication Technology (F3T) incremental forming machine, now located at the John Olson Advanced Manufacturing Center, is special in this field due to its dual-sided operation and its ability to force abnormal geometry via undercutting. The Olson Center has an automation cell capable of milling, turning, plasma cutting, deburring, parts washing, and metrology, but not forming. The goal of this project is to design and install the mechanical, safety, pneumatic, and controls systems to fully integrate the F3T forming machine into the automation cell. To date, the mechanical and safety systems are nearly complete, with pneumatics and controls being the major focus going forward.

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