METAL FORMING WITH FDM TOOLING

Time Required

3D PRODUCTION SYSTEMS

Cost

Skill Level

By Michael Mabie, Stratasys, Inc.

OVERVIEW
Hydroforming and rubber pad press are versatile, metal-fabrication processes used in commercial,
aerospace, automotive and military applications. These manufacturing processes are wellsuited for production of small quantities of sheet metal parts. Both are used for prototype and
development work, one-off custom or repair parts, and low-volume manufacturing.
In aerospace applications, sheet metal is formed into airframe or engine components. In
automotive applications, the parts may be engine cradles, suspension components, radiator and
instrument panel support beams and engine components. Military depots produce many of those
items as well as one-off replacements for the repair of damaged vehicles and aircraft.

Figure 1: Hydroforming press

press. Image
courtesy of Pryer Technologies.

Hydroforming, which is also used for tube forming, presses sheet metal into a female tool or over
a male punch with pressurized liquid. Reaching pressures of up to 15,000 psi (103 MPa), the sheet
metal is forced to take the form of the die. An advantage of this pressure-forming technique is
that complex shapes, such as small undercuts, can be produced. Another advantage is that the
pressure on the mold is uniform in all directions, which can reduce the pressure needed to form
these complex shapes.
The basic operation of the rubber pad press is similar. However, the pressure that forms the sheet
metal comes from a flexible padmade of elastomer or urethanethat deforms as it presses the
sheet into the tool. As a result, the pressures associated with rubber pad press operations are not
uniform like those in a hydroform press. As the height of the part increases, the pressures applied
to the part and the tool will also increase.

FDM FOR METAL FORMING

A new alternative for metal forming tools is the FDM additive fabrication technology. FDM tools
have been shown to be a viable approach that decrease the time and cost for hydroforming and
rubber pad press manufacturing processes (Figure 2). Because of FDMs simplicity of operation
and lights-out manufacturing, new tooling options are available to address the demands of
rapidly changing industries.
The key to successfully forming sheet metal parts in a Fortus 3D production system is the
strength of FDM materials. For example, test data shows that the compressive strength of FDMs
polycarbonate (PC) is 10,000 psi (68 MPa) and Ultem 9085 is 14,000 psi (96 MPa). These numbers
are well within the typical operating pressures of hydroforming (2,000 psi to 10,000 psi/14 MPa to
69 MPa) and 1,000 ton rubber pad press (Figure 3).
By applying FDM to the tool making process, the lead times and costs for some hydroforming
and rubber pad tooling can be decreased. This creates more opportunities to prototype sheet
metal parts and more possibilities for low-volume, or custom, sheet metal manufacturing.
Since the FDM process is additive, increasing complexity has little impact on the time and cost
of the tool. This is ideal for hydroforming sheet metal since it can produce details, such as
undercuts, that are difficult with other metal forming methods. Another advantage that stem from
the additive approach are that tools are constructed in an automated process that needs little
direct labor.

Figure 2: FDM tool forms sheet metal

(top) on 1,000 ton rubber pad press
(center). Finished piece shown in
bottom image.

Fabricators have reported that there are process advantages to FDM tools. The thermoplastics
have an inherent lubricity that eliminates the need to lubricate each metal blank. Also, the FDM
tools do not need a secondary drilling operation to vent pockets that can trap air and result in
back pressure that prevents proper forming.
FDM has been used to make female (blow-down) tools (Figure 4), male (punch) tools (Figure 5)
and pressure intensifiers (Figure 6). When needed for secondary operations, the process can also
construct trim tools and drill templates, sometimes in the same run as that for the related forming
tool.

PROCESS OVERVIEW
Tools constructed in a Fortus 3D production system are direct replacements for conventionally
manufactured hydroforming and rubber pad press dies. Although no process changes are

Figure 3: Sheet metal pan (top)

hydroformed at 8,000 psi (55MPa) in an
FDM Ultem 9085 tool.

REAL APPLICATION

METAL FORMING WITH FDM

PAGE 2

needed, optimization is possible. For example, the properties of FDM tooling can reduce the
number of punch/press cycles for trapped pockets and eliminate the need to lubricate sheet
metal blanks.
Testing results show that suitable hydroforming applications will have forming pressures below
10,000 psi (69 MPa). For rubber pad tools, 1,000 ton presses have been tested for forming of 3.0
in. (76.2 mm) tall parts. However, ongoing testing and optimization may result in higher metal
forming pressures for both processes.
Tested materials include aluminum alloys, stainless steels, titanium, and nickel-based superalloys
such as Inconel. Sheet thicknesses of 0.016 in. to 0.100 in. (0.41 mm to 2.54 mm) have been
formed. In one cycle test, an FDM tool showed no signs of wear or degradation after forming
400 parts in 7075-0 aluminum with 0.090 in. (2.29 mm) thickness.
The FDM process begins with selection of a tooling style, design of the tool and selection of
build material. These decisions will be made, as described below, based on forming pressures.
After designing the tool, it is constructed in a Fortus system. For many tools, lights-out
fabrication will complete in less than 24 hours. After construction, the tool is ready for metal
forming with only support structure removal.

Figure 4: Female (blow-down) tool for

beaded panel.

Figure 5: Male (punch) tool for 90

degree elbow.

DESIGN CONSIDERATIONS AND OPTIMIZATION

1. Metal Forming Process Conditions:
The FDM process, and the design of the forming tool, begins with an evaluation of the part
design and its material. Forming pressures are a function of part geometry, alloy being formed
and the thickness of the stock. As forming pressures rise, adjustments are made to the FDM tool
design. Higher pressures also limit the FDM material options.
If evaluating multiple configurations or alloys for prototype sheet metal parts, it may be best
to be conservative with the FDM process variables. This helps to avoid rebuilding a tool if
unexpectedly high pressures are needed.

intensifier
Figure 6: Pressure intensifi
er for setting
joggles on structural component.

For low-volume production, where design and sheet stock are less likely to change, a
conservative approach may not be warranted, so tool optimization is suggested.
2. Tool Design
As shown in Table 1, three FDM materials
and three tool design alternatives have been
evaluated. For higher forming pressures, Ultem
9085 is recommended. For low pressures,
ABS-M30 is an option. For forming pressures
between 3,000 psi and 8,000 psi (20 MPa and
55 MPa), polycarbonate (PC) is suitable.

Material

Solid

Back Filled
(epoxy)

Optimized *

ABS-M30

3,000 psi
(20 MPa)

Not tested

NA

PC

8,000 psi
(55 MPa)

8,000 psi
(55 MPa)

TBD

Ultem
10,000 psi 10,000 psi
< 5,000 psi
Design options for hydroforming and rubber
9085
(69 MPa)
(69 MPa)
(35 MPa)
pad press tools include solid, back filled
and optimized. The solid design has a metal
Table 1: Hydroforming pressures for various combinations
forming surface and tool body made of FDM.
of tool styles and FDM materials.
The back filled option uses an FDM forming
surface that is backed with an epoxy fill
after the tool is built in a Fortus system. The optimized option uses a forming surface that is
supported by a structural framework, all of which is built in FDM. While a solid tool will offer the
highest resistance to forming pressures, it consumes the most material and takes the longest to
manufacture.

An example of time and cost reduction

is shown in Table 2. For the same sheet
metal part (Figure 7), two forming process
and two tool configurations were used.
A solid, Ultem 9085 tool (Figure 8) for
rubber pad pressing cost $210 and took 10
hours to build. For the same part design,
an optimized design using PC (Figure
9) took four hours less and saved $125.
These savings were possible because the
material and tool design combination could
withstand the 3,000 psi (20 MPa) pressures
of hydroforming.

Tool
Material

Build
Time

Material
Cost

Notes

Rubber
Pad Tool

Ultem
9085

10 hrs

$210

Solid Build

Hydroform
Tool

PC

6 hrs

$85

Optimized build
(produced
parts at 3000
psi/20 MPa)

Figure 7: Sample sheet metal part for

tool configuration study. Part shown on
PC tool (rear).

Fi
Figure
8: Ult
8
Ultem 9085 ttooll ((solid),
lid) with
ith
intensifier cap, for rubber pad press.

Table 2: Optimizing tool design and material selection leads

to time and cost reductions.

*Optimizing methods are dependent on geometry and forming pressures. Contact the DDM Group for assistance
with these considerations.

Figure 9: PC tool (optimized) for

hydroforming.

METAL FORMING WITH FDM

PAGE 3

3. Build Preparation:
All Fortus tools are processed in the Insight software application. No process modifications are
necessary. However, the surface quality of the forming tool can be adjusted by altering either
part orientation or slice thickness.
Rather than building the tool in a horizontal orientation, it can be constructed with the forming
surfaces parallel to the XY plane. This may improve the surface quality, but there may be a
tradeoff in build time. The other option is to select thinner slice thickness.
4. FDM Build:
There are no modifications required for the FDM manufacturing process. The file for the
metal forming tool, and all related components, is built on a Fortus system. When the build is
complete, the tool is removed from the system and support structures are removed. No other
processing is required.

Fi
Figure
10: P
10
Polycarbonate
l
b
tooll ffor
hydroforming an aluminum disk at
5,000 psi (34 MPa).

5. Tool Finishing:
For sheet stock with thicknesses greater than 0.040 in. (1.02 mm), the surface quality of the FDM
tool will be suitable for most applications, even when constructed with 0.010 in. (0.25 mm) slice
thickness. However, there are finishing options that can improve the surface quality of the sheet
metal part, if needed.
The surface of the FDM tool may be sanded to prevent transfer of tool paths and layer lines to
the formed metal part. Alternatively, the surfaces may be machined with a light finishing pass on
a CNC mill. However, if machining the tool, machine stock must be added to the design (before
building in FDM) to account for material removal.
Another alternative that requires adjustment to the tool design is to use sheet metal stock to
create a smooth forming surface in the tool. Select a thin sheet of metal, 0.040 in. (1.02 mm)
or less, and form it into the FDM tool with the hydroforming or rubber pad press process. This
sheet will be left in place after formingthe tool will now be a hybrid of FDM thermoplastic and
sheet metal. The CAD design adjustment that is required is an offset of the tooling surface by
the thickness of the sheet metal that will go into the tool.
6. Tool Try-Out and Adjustment:
Determining the outcome of a sheet metal forming operation calls upon science and experience.
But the end result is rarely predictable to production specifications. Springback and tolerance
are two examples of variables that change with the alloy, sheet thickness and part configuration.
So, every tool includes a try-out process where the end result is measured and adjustments are
made.
Constructed in thermoplastics, the FDM forming tools are easily adjusted with light milling or
hand working. Early in the trial forming process of complex parts, folds and wrinkles can cause
gouges to the surface of the tool. Like their metal counterparts, FDM tools can be repaired with
welding techniques that replace damaged areas with parent material. Unlike metal tools, welding
is done with a simple, low-cost, low-temperature hot air device. This flexibility to easily repair and
adjust the tool can make metal forming an iterative process that does not add significantly to
time or cost.
If iterations are no longer feasible, because a design has changed significantly or an alternative
tool configuration is needed, the FDM build process is simply repeated. In less time than it takes
to make one conventional die, a female, blown-down tool could be evaluated and replaced with
an alternate male tool to address forming issues.

TESTING DATA
The information in this guide was developed in cooperation with:
Pryer Technology Group
Several U.S. Military Depots
Ohio State University - Engineering Research Center for Net Shape Manufacturing (ERC/NSM)
Blow-Down Tool
A solid polycarbonate blow-down tool (Figure 10) produced a 15.0 in. (336 mm) diameter, 1.25 in.
(31.8 mm) deep disk in 7075-0 aluminum. Hydroforming pressure of 5,000 psi (34 MPa) was used.
For this piece, a single pressure cycle was used. With conventional tooling, five cycles were
required because of trapped air in the four pockets.
Structural Part Coordinated Tool Family
To form the structural component (Figure 11), a male tool, pressure intensifier and trimming tool
were produced with a Fortus 3D production system.
Without an intensifier, 6,000 psi (40 MPa) would be required to form all of the features in this
part. With the use of an FDM intensifier, the part, including joggles and lighting holes, was

Figure 11: Structurall component

formed in 2024-0 aluminum. A) Ultem
9085 female tool and intensifier B)
Initial forming on FDM tool C) Pressure
intensifier to be applied D) FDM guide
for trimming operation.

METAL FORMING WITH FDM

PAGE 4

formed with 3,000 psi (20 MPa). The finishing step was trimming of the raw sheet metal part
using an FDM-made guide.

FDM (fused deposition

modeling) is a direct digital
manufacturing process patented
by Stratasys, Inc.

Testing Data Summary

FDM Tool

Conventional
Tool

Part

Cost

Lead
Time

Cost

Lead
Time

Cost
Savings

Lead Time
Reduction

Structural
Component

$450

1 day

$1500

35
days

70%

67% to 80%

Pan

$325

1 day

$800

25
days

59%

50% to 80%

25
days

61%

Elbow

$464

1 day

$1200

Structural Component

Pan
50% to 80%

Table 3: Time and cost comparison for hydroforming three sheet metal parts.
Elbow

Material

Build
Time
[hours]

Forming
Pressure
[psi/MPa]

Maximum
Test
Pressure
[psi/MPa]

Estimated
Tool Life

Materials Formed
[thickness: in./mm]

Structural
Part

Ultem
9085

14

3,000

10,000

100+

2024-0 Al (0.063/1.60)

Pan

Ultem
9085

13

8,000

8,000

100+

2024-0 Al (0.050/1.27)

Elbow

PC

24

7,500

7,500

50+

2024-0 Al (0.040/1.02)

2024-0 Al (0.090/2.29)

347 SST (0.020/0.51)

2024-0 Al (0.063/1.60)
347 SST
Table 4: Performance data from hydroforming tests on the sheet metal parts listed in Table 3.

CONCLUSION
Forming sheet metal parts with thermoplastic tools is counter-intuitive. At first, it does not seem
possible that stainless steel and Inconel can be formed by an FDM tool with 10,000 psi (68 MPa)
pressures. However, testing at Pryer Technologies, industry partners and several military depots
has proven it possible and advantageous.
The efforts of these organizations has led to process optimization that further decreases the
time and cost of two metal forming alternatives that are faster and more affordable alternatives
to sheet metal stamping. Having shown that it is possible, companies can now use FDM tooling
in their hydroforming and rubber pad press operations to decrease time and cost while gaining
other process advantages.

For more information about Fortus systems, materials and applications, call 888.480.3548 or visit www.fortus.com
Fortus 3D Production Systems
Stratasys Incorporated
7665 Commerce Way
Eden Prairie, MN 55344
+1 888 480 3548 (US Toll Free)
+1 952 937 3000
+1 952 937 0070 (Fax)
www.stratasys.com
info@stratasys.com

FDM PROCESS DESCRIPTION

Fortus 3D Production Systems

Stratasys GmbH
Weismllerstrasse 27
60314 Frankfurt am Main
Germany
+49 69 420 9943 0 (Tel)
+49 69 420 9943 33 (Fax)
www.stratasys.com
europe@stratasys.com

2010 Stratasys Inc. All rights reserved. Stratasys and FDM are registered trademarks and Fortus, Real Parts, Fortus 360mc, Fortus 400mc,
Fortus 900mc, Insight, Control Center and FDM TEAM are trademarks of Stratasys Inc., registered in the United States and other countries.
*ULTEM 9085 is a trademark of SABIC Innovative Plastics IP BV. All other trademarks are the property of their respective owners. Product
specifications subject to change without notice. Printed in the USA. AG-METAL FORM 01/10

The FDM process creates

functional prototypes,tooling
and manufactured goods from
engineering thermoplastics,
such as ABS, sulfones, and
polycarbonate, as well as medical
versions of these plastics.
FDM machines dispense two
materialsone for the model
and one for a disposable support
structure. The material is supplied
from a roll of plastic filament
on a spool or in a cartridge. To
construct the model, the filament
is fed into an extrusion head and
heated to a semiliquid state. The
head then extrudes the material
and deposits it in layers as fine as
0.005inch thick.
Unlike some additive fabrication
processes, FDM requires no
special facilities or ventilation and
involves no harmful chemicals
and byproducts.