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Rapid Prototyping of Sheet Metal Body Parts


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Guest Magoo
Posted
Interesting. I always wondered how small-volume body parts are made (Ford Model T parts, for example). Is a full-size stamping die made for each part? Other low-volume methods are hydroforming, superplastic forming and (of course) beating! Here is a video forming a wheel well from an older car: Kirkham University Superplastic Forming Aluminum Coupe Rear Wheel Well - YouTube

Phil

To my knowledge, all the volume repop sheet metal parts in the biz today are pressings done with dies on big presses in the traditional auto industry manner. Accurate and authentic but requires a substantial investment in mfg. equipment and tooling. One cost savings for short runs involves kirksite dies -- cheaper but short production life. Superplastic and hydroforming require forming dies as well.

The interesting and powerful aspect of the method above is it goes straight from art to part with no tools. If you possess the component in math form (or can digitally scan it from an existing part) then this process can hand you a finished part. This is the sheet metal analogue to CNC for machined parts. It doesn't appear ready for deep draws and complex shapes, but stuff like rust repair panels would be a cinch. Will be interesting to see how this progresses.

Posted

The really interesting thing about this type of rapid prototyping is that it is advancing at a rapid rate. Five years from now it will probably be common. Twenty years from now, car clubs may have their own machines. Looking forward to this.

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