Misforming

Misforming is the act or result of forming something in an incorrect or unintended shape. It describes a deviation of a formed part from its intended geometry or properties that arises during a forming process, due to errors in tooling, process parameters, material behavior, or handling.

In manufacturing and engineering, misforming can occur in metal forming (forging, stamping, extrusion), plastic forming (injection molding, thermoforming), or ceramic shaping. Causes include improper die design or clearance, wrong temperature or pressure, incorrect speed, tool wear, misalignment, material inconsistencies, or inadequate lubrication.

Consequences include dimensional inaccuracy, geometric distortion, surface defects, residual stresses, and reduced strength or performance. The part may be scrapped or require rework. Common manifestations include wrinkles, folds, warping, or flash in metal parts; sink marks or short shots in plastic parts; and chipping or cracking in ceramics.

Prevention and detection combine design for manufacturability, process simulation and capability analysis, strict process controls, inspection and nondestructive testing, and corrective actions based on feedback. When misforming is detected early, parameter adjustments or redesign of tooling can reduce waste.

See also: manufacturing defect, forming defect, process capability, quality control.