What’s Incremental Sheet Forming?

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Incremental sheet metal forming is a three-dimensional (3D) sheet metal forming process that can produce a wide variety of prototypical or deliverable items with excellent flexibility and low cost values. Unlike other processes, incremental sheet metal forming does not use a set of dies to physically punch the part from sheet metal. In this process, a three-dimensional computer numerically controlled (CNC) milling machine moves a shaped bit around the sheet, gradually imprinting an image on the sheet in pre-set increments. The movements of the machine are controlled by a computer using a 3D computer-aided design (CAD) model of the part as a reference. The fact that the process does not use expensive machining techniques to produce dies makes it one of the most cost-effective methods of forming sheet metal.

Sheet metal forming is a common method of producing a variety of positive finished products or negative molds used in finished item casting. These techniques are used to produce both commercial distributable products and as an additive prototyping method. Most conventional sheet metal forming is achieved using a series of dies consisting of positive and negative halves placed in a press. The sheet metal is placed between dies, which are then pressed together to form the part. While effective and accurate, this method requires a large initial financial outlay to set up the molds and requires large production quantities to justify the costs. Incremental sheet metal forming is a relatively young technology that produces comparable results at a fraction of the cost.

The incremental sheet metal forming process uses a 3D CNC machining station controlled by a CAD model of the desired part. Similar to a conventional milling machine, this machine features a spindle fitted with a custom shaping tool bit. The machine advances the tip of the tool over the surface of the sheet, tracing the shape of the piece as it goes. With each pass, the tip of the tool descends in gradual, set increments, slowly pressing the desired shape into the sheet. The machine can be programmed to increase or decrease the number of increments and the distance between each pass, creating either a rough, stepped part or one with a smooth surface.

The nature of incremental sheet forming is inherently economical and precise, due to the accuracy required and the lack of costly mold manufacturing. Using this process, stock parts can be produced quickly from standard size sheets when the need arises, without having to undertake large production runs. This has a significant cost implication for companies that require low-volume on-demand manufacturing or for those looking to produce sheet metal prototype parts.

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