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design experiment applying incremental sheet metal forming FH Potsdam product designincremental | Fraunhofer Institut IWU design experiment applying sheet metal forming FH Potsdam product design | Fraunhofer IWU


Incremental sheet metal forming is a technique where a sheet is formed into the final workpiece through a series of small incremental deformations. In a stepwise procedure a round tipped tool forms a contour in the metal sheet and continues to draw contours in the sheet until the final shape is reached.


design experiment experiment applying applying incremental design incremental sheet sheetmetal metalforming forming FH FH Potsdam product design | Fraunhofer Institut Potsdam product design | Fraunhofer IWUIWU

metalscapes is an interdisciplinary research project from the University of Applied Science Potsdam in cooperation with the Fraunhofer Institute for Machine Tools and Forming Technologies IWU Chemnitz. Industrial Design students from the FH Potsdam created a series of design experiments using incremental sheet metal forming. The resulting objects were shaped using ultra lightweight aluminum sheet metal. Six different approaches were used to explore the potential of this innovative technology at the crossroads of product design and engineering. The technology’s inherent advantages, such as fast prototype developments without high tool costs, allowed the students to explore and challenge this technique and discover its unique potential. Its uses include real-time processing of transforming digital data into a three-dimensional metal surface and the production of individualized medical devices resulting from a 3D body-scan, just to name some. The exhibition does not aim to display final products. Rather, it shows concepts that are still in development and are seen as inspirations and starting points for new research projects. The metalscapes cooperation illustrates the relevance and potential of applied research in design and highlights the strength of the designer as an experimenter and innovator. The partnership highlights the importance of an alliance between design, engineering, and production in the development of new materials, technologies, and their applications. Fraunhofer IWU The Fraunhofer Institute for Machine Tools and Forming Technology IWU is one of the world’s most important research and development institutes in the field of manufacturing science. Approximately 520 highly qualified staff based in Chemnitz, Dresden, and Augsburg conduct research in the core areas of adaptronics, mechatronics, machine tools, cutting technology, forming technology, joining and assembly technology, and virtual reality.

Project supervision: Prof. Hermann Weizenegger / FH Potsdam Dipl.-Des. Jörg Höltje / Studio Hausen Graphic design: Eva Lechner

Fraunhofer IWU: Dipl.-Ing. Dieter Weise Dipl.-Ing. Peter Scholz

Photography: Julian Faust

Industrial Design students from the FH Potsdam: Stefan Aufrichter, André Diekneite, Grischa Guzinski, Jonas Hagenbusch, Tilo Krüger, Jana Marlene Lippert, Julia Oberndörfer, Heiko Rintelen, Hendrike Roers, Robert Vogel, Max Wosczyna, Bernadette Wüchner Potsdam/Berlin/Chemnitz 2013 design.fh-potsdam.de www.iwu.fraunhofer.de The University of Applied Sciences Potsdam declares that the Fraunhofer Institute is neither the editor of the advertising medium, nore do they accept liability.


design experiment experiment applying applying incremental design incremental sheet sheetmetal metalforming forming FH FH Potsdam product design | Fraunhofer Institut Potsdam product design | Fraunhofer IWUIWU

Incremental sheet metal forming is a technique where a sheet is formed into the final workpiece by a series of small incremental deformations. In a stepwise procedure a round tipped tool forms a contour in the metal sheet it continues to draw contours in the sheet until the final shape is reached.

Concept Incremental metal forming is a technique that allows the quick and simple manufacture of asymmetric, semi-finished products and tools based on digitally produced data. It also enables spontaneous alterations that make it possible to produce different shapes and surfaces. Raw forms are the point of departure for a continuous, interactive production process in which incremental metal forming is establishing itself as an accepted technique for a network of diverse manufacturers. An interdisciplinary collaboration between technology and craft is being developed with mutual inspiration and development as its aim. We as designers are present at the beginning of this process. The development of raw forms leads to the emergence of diverse products, the aesthetic and function of which can be developed according to different crafts. Vi s i o n Incremental metal forming is becoming a common technique within the production process of a dense craft network. Financial and intellectual investment in a technology makes possible intense collaboration and an exchange of expertise. The result is exciting products that show a multifaceted production process. This all takes place at a location in which incremental metal forming is the focus, and around which craftspeople can assemble. The designer is understood as an equal partner within this network who, through their training, not only creates geometries but also stimulates and optimizes complex processes and takes charge of communication and documentation.

Andre Diekneite , Julia Oberndรถrfer

ROHFORM http://design.fh-potsdam.de/


design experiment experiment applying applying incremental design incremental sheet sheetmetal metalforming forming FH FH Potsdam product design | Fraunhofer Institut Potsdam product design | Fraunhofer IWUIWU

Visualization of Formula One Racing Data through Incremental Sheet Metal Forming Data Trophy combines the intrinsic value of the driver’s influence over a race’s outcome with the technological aspirations of motorsports itself, especially in Formula One competition. Huge amounts of data are obtained during every instant of a race. This so called Telemetry Data is screened and analyzed by mechanics and engineers to optimize the car and the driver’s performance accordingly. Our aim is to generate a highly personal product in the form of a Formula One Winner Drivers Trophy through combining the visualization of Telemetry Data with the innovativeness of Incremental Sheet Metal forming. Its ability to quickly translate 3D data into physical objects makes our concept feasible. Right off the track Data Trophy’s form originates from three data sets that are influenced directly by the driver during track time : RPM, speed, and even g-forces. A set is then visualized and produced as one of three patches. The final form of the trophy is formed through merging so that it mirrors the uniqueness of the competition’s winner — as if the driver has created their own trophy.

Incremental sheet metal forming is a technique where a sheet is formed into the final workpiece through a series of small incremental deformations. In a stepwise procedure a round tipped tool forms a contour in the metal sheet and continues to draw contours in the sheet until the final shape is reached.

Stefan Aufrichter, Robin Hohn, Tilo Krüger, Stephan Schmidt

DATATROPHY http://design.fh-potsdam.de/


design experiment experiment applying applying incremental design incremental sheet sheetmetal metalforming forming FH FH Potsdam product design | Fraunhofer Institut Potsdam product design | Fraunhofer IWUIWU

Due to the reflective properties of polished metal, we envisioned a large reflective surface that absorbs available daylight and light from spotlights and reflects it onto darker corners of a room. Incremental sheet forming (pressing large areas without forms) should make such an individual and adaptive light sculpture possible. However, while we were building little models with paper, we had an idea for a lamp that reflects light over metal surfaces selectively in certain directions. The model reflectors made ​​of paper were changed until “Polylight” was created. It is a metal light that is folded from a surface into the third dimension. Characteristics of the light include its polygonal surface structure, its sculptural appearance, and its special light shaping : The primary light in the center produces homogeneous illumination on the work- or dining table. Four spots are responsible for cozy, indirect light that radiates against reflective inner surfaces, which reflect light both up and down. Two separate circuits enable it to switch between two different lighting moods. This idea could be used on customized light screens for special applications that would be formed and calculated accordingly.

Incremental sheet metal forming is a technique where a sheet is formed into the final workpiece through a series of small incremental deformations. In a stepwise procedure a round tipped tool forms a contour in the metal sheet and continues to draw contours in the sheet until the final shape is reached.

Heiko Rintelen, Hendrike Roers

POLYL IGHT http://design.fh-potsdam.de/


design experiment experiment applying applying incremental design incremental sheet sheetmetal metalforming forming FH FH Potsdam product design | Fraunhofer Institut Potsdam product design | Fraunhofer IWUIWU

Incremental sheet metal forming is a technique where a sheet is formed into the final workpiece through a series of small incremental deformations. In a stepwise procedure a round tipped tool forms a contour in the metal sheet and continues to draw contours in the sheet until the final shape is reached.

Selective Incremental Sheet Forming SIBU Forming through minimal Impact Selective sheet forming involves impacting the sheet metal only at the exact spots where a function is needed. Similar to the venation of plant leaves, the structure, which consists of patterned crosses, braces the surface. Due to the internal stress of the material, the gap surfaces between the crosses bulge, giving the metal an uncommon plasticity. By joining function and ornamentation, a specific language is developed that illustrates the sheet metal’s power. The structure can thus be adapted to different demands, for instance for light weight facades or hanging constructions. We provided an example of one of its constructive applications when we created the “vena” swing. The “costa” chair shows another advantage of SIBU. In contrast to conventional edge bending methods for sheet metal, a bead is pressed into the surface along a curve, which immediately causes the material to rise. No expensive mold is needed to give the metal a three dimensional, yet organic form. Forming a skeleton of outlines and beads, the surfaces in between stretch and bulge into a functional form, creating an ideal structure for the material. Step by step, the seat “grows” from the flat sheet. The method benefits a range of functional and aesthetic design applications simply through the interaction of a few lines.

Max Wosczyna, Bernadette Wüchner

SIBU http://design.fh-potsdam.de/


design experiment experiment applying applying incremental design incremental sheet sheetmetal metalforming forming FH FH Potsdam product design | Fraunhofer Institut IWU Potsdam product design | Fraunhofer IWU

A collective of three young designers that see themselves as a bridge between cultures invites users to actively participate in the product life-cycle. Open Source—The products can be freely modified, which allows the customer to choose how far they want to realize its potential. In cooperation with the Frauenhofer Institute Chemnitz, Smart Shaped creates molds using incremental sheet metal forming. The potential of this procedure lies in the conversion of flowing forms onto sheet metal, the possibility of subsequent modification, and the reduction of tool costs by implementing this procedure. A single mold can be used for the mass production of different products, which enables holistic designs of spacial sceneries. As its premier design concept, Shape 1.0 will be presented at the DMY 2013. Incremental sheet metal forming is a technique where a sheet is formed into the final workpiece through a series of small incremental deformations. In a stepwise procedure a round tipped tool forms a contour in the metal sheet and continues to draw contours in the sheet until the final shape is reached.

Grischa Guzinski, Jonas Hagenbusch, Robert Vogel

SMART SHAPED http://design.fh-potsdam.de/


design experiment experiment applying applying incremental design incremental sheet sheetmetal metalforming forming FH FH Potsdam product design | Fraunhofer Institut Potsdam product design | Fraunhofer IWUIWU

Every day we use clothes, jewelry, and accessories to express ourselves. When an injury occurs, we are sometimes forced to wear a medical implement over a longer period of time. Our self-design is thus thrown out of balance because we are wearing an object that communicates only one message to the world : I am ill ! The Closer Project is closely tied to the body. Using 3D-livescan technology, a blank brace is virtually fit to the affected body and then pressed using incremental sheet metal forming. The precise fit to the body, the lightness of the aluminium, as well as its metallic surface speak to its quality and overlaps with the world of jewelry-like objects. The goal is not to conceal the injury but to give its wearer the possibility to integrate it as a decorative object into his / her own style. Incremental sheet metal forming is a technique where a sheet is formed into the final workpiece through a series of small incremental deformations. In a stepwise procedure a round tipped tool forms a contour in the metal sheet and continues to draw contours in the sheet until the final shape is reached.

Jana Marlene Lippert

CLOSER http://design.fh-potsdam.de/



Metalscapes