Classic Car Parts
This case study demonstrates the benefits of a dieless forming method for small batches of parts, and the ability for ISF to be used when a production run has ended and a desired die can no longer be sourced.
Background: replacement panels for classic cars
Maintaining classic cars is an ever-increasing challenge. As components age, they begin to fail and finding replacements becomes more difficult.
ISF could be used to produce parts that are no longer in production. External body panels in particular are traditionally produced using die-based sheet forming and are ideal for ISF.
A similar use case is for car customisation. As most automotive components are generic and mass produced, ISF could be used to create more complex parts to customise a car for performance or aesthetic purposes. Small batches could be created with high time and cost efficiency, and could also be iteratively tweaked and improved per run.
ISF Steps
The geometry of the car's body panel is designed in CAD software.
The geometry is adapted to be manufactured using ISF.
A toolpath is generated to be used by a CNC machine.
The part is formed.
The part is finished, painted and fitted.
Benefits
ISF offers the cheapest method of producing a car panel no longer in production.
The small-batch flexibility of the process would facilitate contributions from small businesses and hobbyists.
The use of steel in ISF has already been widely investigated, demonstrating good formability.
Viability
Geometry may have to be adapted slightly to be produced by ISF. For example, wall angles cannot exceed the maximum forming angle of the material in use.