About Digital Sheet Forming
Digital Sheet Metal Forming Technology | Deep Draw Sheet Metal Forming
Digital Sheet Metal Forming (DSMF) is one of the latest advancements in our field, and it offers numerous benefits for businesses looking to streamline their production and reduce manufacturing time. Compared to traditional manufacturing methods with sheet material, DSMF offers advantages including shorter lead times, faster production, elimination of expensive tooling and die manufacturing, and lower overall cost versus traditional parts stamping. Additionally, Digital Sheet Metal Forming has virtually no minimum order quantity (MOQ) meaning that its perfect for unique projects and rapid sheet metal prototyping.
Digital Sheet Metal Forming Capabilities
The Formable Area
Our Figur G15 Digital Sheet Metal Forming Machine from Desktop Metals is capable of forming parts up to 57.1 inches x 39.4 Inches (1,450 x 1,000 mm).
Formable Materials We Support
| Currently Supported Materials | |||
|---|---|---|---|
| Material | Maximum Thickness | ||
| Cold Rolled Steel — Up to: | 0.079 in. | 2mm | 14ga. |
| Aluminum - 6061 TO — Up to: | 0.125 in. | 3.175mm | 9ga. |
| Materials in Development | |||
| Material | Maximum Thickness | ||
| Stainless Steel - 301 — Up to: | 0.079 in. | 2mm | 14ga. |
| Stainless Steel - 304 — Up to: | 0.079 in. | 2mm | 14ga. |
| Copper | 0.022 in. | 0.55mm | 24ga. |
| Aluminum - 1100 TO — Up to: | 0.063 in. | 1.6mm | 14ga. |
| Aluminum - 2024 TO — Up to: | 0.125 in. | 3.175mm | 9ga. |
| Aluminum - 5052 TO — Up to: | 0.083 in. | 2.1mm | 12ga. |
| Future Materials | |||
| Inconel | |||
| Gold | |||
| Titanium | |||
Material Thinning
During the Digital Sheet Metal Forming process the material will be incrementally thinned as it forms. This material thinning is based on the wall angle of the part design.
Oversized Designs
For parts that are larger than the maximum formable area of the Figur G15 machine, designs can be split into multiple parts. This split typically takes place between two parallel walls that are greater than 60 degrees.
Applications
Our Experience and Capactity
Expertise in Digital Sheet Metal Forming (DSMF)
Our direct experience with Digital Sheet Metal Forming has allowed us to cater to a wide range of industries, from aerospace and automotive to medical and consumer goods. We have successfully delivered custom prototypes and final products that have exceeded our clients’ expectations, showcasing the versatility and effectiveness of this manufacturing method.
Whether it’s for rapid prototyping or high-volume production, our expertise in Digital Sheet Metal Forming enables us to provide our clients with cost-effective and timely solutions for their additive manufacturing needs. With Evology Mfg. on your side, you can be confident in the quality and reliability of the products we deliver.
Frequently Asked Questions
Digital Sheet Metal Forming is a manufacturing technique utilized to shape sheet metal efficiently without the need for traditional tooling. By using a single point tool, this process creates intricate contours, commonly seen in automotive body panels, industrial components, or aircraft structures, into the metal. With precise control and relatively low consumable tooling costs, Digital Sheet Metal Forming is ideal for small to medium-sized production batches and rapid prototyping. Digital Sheet Metal Forming offers accuracy, repeatability, and flexibility in creating complex shapes.
Simply put, to avoid the huge barrier to entry with long lead times and expensive tooling. Digital Sheet Metal Forming streamlines the manufacturing process, reducing overhead and lowering the overall cost of production. Additionally, Digital Sheet Metal Forming is flexible and allows for on-demand production.
Digital Sheet Metal Forming is a perfect solution for creating various parts from a variety of industries. While typically used in the aircraft and automotive industries, Digital Sheet Metal Forming can also craft things like bowls, light fixtures, signs, and more!
While Digital Sheet Metal Forming is an incredible technology, it does have its limitations. Ideal parts for this technology are smooth, have less than 60 degrees of draft, and have no large flat areas.
Easy
- Smooth
- 60 degree draft
- No peaks and valleys
- No large flat areas
Medium
- Smooth
- Peaks and valleys
- 60-75 degree walls
Difficult
- Steeper wall angles, 70 – 90 degrees
- Convex geometry within the part
- Large flat areas
As of March 2024 the Figur G15 supports cold rolled steel up to 2mm thick as well as 6061 aluminum up to 3.175mm thick, with other materials such as 301 and 304 stainless steel, copper, and various other aluminum alloys being in development.
While part tolerances depend on several factors including part complexity, material type, part orientation, and tooling, the general accuracy of Digital Sheet Metal Forming technology is between 0.5%-2% of the largest dimension of the part. Additionally, the detail of the radiuses in the part should be 2-3x the radius of the tool for best results.
Currently the Figur G15 has a maximum formable area of 1450mm x 1050mm x 400mm (57.1 in. x 39.4 in. x 15.75 in) however larger parts can be formed with the machine by simply splitting the design into multiple pieces. This is often done by splitting the design along 2 parallel walls that are greater than 60 degrees.
Digital Sheet Metal Forming can manufacture materials up to 3.175mm in thickness.
Transform Your Projects with Digital Sheet Metal Forming
Are you looking for a rapid tooling solution that combines speed, strength, and flexibility? Our Digital Sheet Metal Forming services are here to bring your ideas to life. Contact us to discuss how DSMF can benefit your next project.