This paper explores the development and application of the incremental forming process, an innovative method for manufacturing complex parts with high flexibility and low tooling costs. The review categorizes three key process variants: Single Point Incremental Forming (SPIF), Two Point Incremental Forming (TPIF), and Incremental Forming with Conjugated Active Plate (IFCAP). This study demonstrates the significant effects of these process variants on part accuracy and material behavior, particularly under varying process conditions. This study identifies critical technological parameters such as tool diameter, feed rate, and vertical step size. The findings also demonstrate the role of optimized toolpaths and lubrication in improving process efficiency. Applications of incremental forming across various industries, including automotive, aerospace, medical, and construction, demonstrate its versatility in prototype production and small-series manufacturing. These results contribute to a deeper understanding of incremental forming, offering practical recommendations to enhance precision, scalability, and material formability, and supporting future innovations and broader industrial applications.

To achieve a 3D shape with certain degree of complexity from metal sheets that are flat in the beginning, especially for prototype development or small series production, that is also cost efficient by avoiding high-end dies or expensive tooling, the incremental sheet forming process can represent the ideal choice due to its flexibility, reduced forming forces and increased formability. The process is performed with a round tool that follows a predefined path to deform the flat metal sheet into its final shape. The proper selection of the toolpaths affects the productivity and the accuracy of each part. The process having to focus on forming each single point in increments. For cost-effective production, the incremental sheet forming process is performed by an industrial robot. This paper aims to showcase the superior kinematic potential of the robot for complex tool paths by means of simulation. Singularity issues and robot joints limitation is checked through DELMIA software platform. After the design, simulation, and generation of the tool path, the software code can be generated and also used to steer the robot.

The present paper aims to study the behavior of tailor welded blanks subjected to a single point incremental forming (SPIF) process from an experimental point of view. This process was chosen to deform truncated cone shapes of AA1050 aluminum alloy with different thicknesses. A uniaxial tensile test was performed to determine the mechanical characteristics of the alloy. Initial experimental tests implicated the use of variable wall angle parts which were processed on unwelded sheet blanks for determination of the behavior of the material and the forming forces. Afterwards, the wolfram inert gas (WIG) welding technique was used for joining two sheet blanks with different thicknesses either through one pass on one side, or by one pass on both sides. The conclusion of this paper indicates that one-sided welded blanks cannot be deformed successfully without fracture. In case of two-sided welded blanks, the results showed that the desired depth of 25 mm can be reached successfully. In case of the SPIF process, if welded blanks must be deformed, then the suitable method is to weld the blanks on both sides.

The present paper highlights the importance of generating a model for analysing the caulking process. The caulking operation is a fast, cost-efficient, cost-effective way of assembling, which is currently less studied in world-wide papers. The operation is at the border between plastic deformation and cutting process. It is therefore necessary to create a model to describe the process. In the paper are presented the main examples of applications, the main parameters that characterize the process, the current state of the cutting and plastic deformation models. After the analysis we concluded that the most valuable model for describing plastic deformations is the Johnson-Cook model. This information is the basis for developing a model for describing the caulking process.

The present paper aims to study the behaviour of Metal Active Gas (MAG) tailor welded blanks during the single point incremental forming process (SPIF) from an experimental point of view. The single point incremental forming process was chosen for manufacturing truncated cone and truncated pyramid shaped parts. The same material (S355) and the same thickness (0.9 mm) were selected for the joining of blank sheets because the main goal of the paper was to study the influence of the MAG welding process throughout the SPIF process. A Kuka robot, equipped with a force transducer and an optical measurement system were used for manufacturing and evaluating the parts by SPIF. The selected output data were major and minor strain, thickness reduction, forces and springback at the SPIF process. Another line test was performed to evaluate the formability in SPIF. The main conclusion of the paper is that during the SPIF process, fractures occur in one side welded blanks even at moderate wall angles, while in the case of double side welded blanks there is a decrease of formability but parts can still be produced at moderate angles (55 degrees) without any problems.

Nowadays, there is a high demand for rapid prototyping parts and for products manufactured through plastic cold deformation. Incremental forming process is one of many which presents numerous advantages for fast production of complex shape parts. The purpose of this study is to develop a numerical model through finite element analysis to simulate the incremental forming process. For this analysis a variable wall angle part (VWA) which ranges from a 45° wall angle at the higher base of frustrum cone to a 70° wall angle at the base of the shape was proposed. The numerical model showed where the maximum strains are localized, how big the forces are during the process and how much the material thinned. Although the model does not indicate a possible failure of the material, the integrity of the structural stiffness was altered due to a minimum thickness reached of just 0.26mm.