Incremental Sheet Forming(ISF)

Overview

Incremental Sheet Forming (ISF) is a manufacturing process used to shape sheet metal into 3D components through a series of localized deformations. Unlike traditional forming methods that use dies or molds to shape entire sheets of metal in one operation (like stamping or deep drawing), ISF works by incrementally deforming small regions of the sheet at a time.

Incremental Sheet Metal Forming in Architecture by Research developed by Ammar Kalo and Michael Jake Newsum

How it works

Incremental Sheet Forming (ISF) can be performed using different types of machines, depending on the specific application and the scale of production. At the FabLab we use a CNC machine for our ISF services.

CNC machines operate by controlling the movement of forming tools with high precision and flexibility. CNC machines follow programmed instructions to gradually shape sheet metal into desired 3D geometries through incremental deformation. The process begins with CAD/CAM software, where digital models are translated into tool paths and machining instructions. During operation, the CNC system precisely positions the forming tool over the sheet metal, adjusting feed rates and tool depths according to programmed parameters. This automation ensures consistent part quality and dimensional accuracy across production batches. CNC technology in ISF allows for efficient manufacturing of complex shapes, supports rapid prototyping, and facilitates customization by adapting to various sheet metal materials and thicknesses.

Key features

Incremental Deformation: The forming tool moves over the surface of the sheet metal, deforming it incrementally, usually with a CNC-controlled spindle or robot arm.

Localized Force Application: ISF applies force locally, which allows for more complex shapes to be formed without the need for complex and expensive dies.

Flexibility in Design: Because ISF doesn't require fixed dies, it offers flexibility in producing prototypes, small batches, or customized parts with quick setup times.

Material Usage Efficiency: It can be more material-efficient compared to traditional forming methods since it doesn't require the entire sheet to be worked on simultaneously.

Suitability for Complex Shapes: ISF is particularly suitable for forming complex shapes and parts with varying wall thicknesses.

Process Control: The process typically involves computer control, allowing for precise adjustments and potentially automated production.

Applications: ISF finds applications in industries such as aerospace, automotive, and manufacturing, architecture and interior design where complex geometries and low-volume production are common requirements.

Once you have chosen the right printer for your job, you can use the Quick Start Guide to prepare and submit your file:

ISF Guide