formmaterials

Formmaterials is a term used in manufacturing engineering to refer to the materials that are used as forming tools and surfaces to impart shape to a workpiece during forming, molding, or casting processes. The formmaterial provides the negative or positive geometry that defines final dimensions, while also affecting surface finish and dimensional stability. Examples include tool steels and carbides used for dies in metal forming; ceramics and graphite used for hot-work and casting molds; elastomeric and polymeric coatings and liners that regulate friction and wear; and ceramic or glass molds in high-temperature forming.

Selection criteria for formmaterials emphasize hardness and toughness, thermal stability, wear resistance, chemical compatibility with the workpiece and process fluids, and compatible thermal expansion. Machinability and cost are also important considerations. Formmaterials often employ surface engineering, coatings, or composite structures to extend life and improve performance. In practice, the material choice is tailored to process conditions such as temperature, pressure, and lubrication, and may incorporate allowances for wear and dimensional change over time.

Applications span metal stamping and forging, plastic injection and compression molding, glass and ceramic forming, and composite layup molds used in aerospace and automotive industries. Ongoing research in formmaterials includes developments in ultra-hard ceramics, advanced tool steels with engineered microstructures, functionally graded materials, and additively manufactured mold inserts, all aimed at increasing tool life and dimensional fidelity.