sheetforming

Sheet forming is a class of manufacturing processes in which sheet-like materials are shaped by plastic deformation. It covers operations that either form sheet stock into parts or produce sheet products from billets, foils, or continuous feed. Core sheet-forming processes include rolling to produce sheet stock, and subsequent forming steps such as bending, stamping, deep drawing, hydroforming, and thermoforming. Calendering, extrusion leading to sheet, and stretch forming are also used to create or shape sheets.

Materials commonly treated by sheet forming include metals (such as steel, aluminum, copper, and titanium), polymers (thermoplastics such as PET and polypropylene), composite laminates, and thin ceramic sheets produced by tape casting and related methods. Equipment ranges from rolling mills and presses with dies to specialized thermoforming machines, hydroforming equipment, and calenders. Process parameters include sheet thickness, thickness uniformity, surface finish, temperature (for hot or thermoforming), forming speed, and lubrication or friction conditions. Quality measures focus on thickness tolerances, flatness, and the absence of defects such as wrinkling, tearing, springback, or surface blemishes.

Applications span automotive panels, appliances, building envelopes, packaging films, electrical enclosures, and consumer products. Advantages of sheet forming include high production rates and good dimensional control for flat parts, with material efficiency. Drawbacks can include high tooling costs, springback in metals, limits on geometric complexity, and energy requirements. The technology has matured through advances in rolling, stamping, and thermoforming, enabling wide industrial use.