Exploring advancements in incremental sheet metal forming: a review

Incremental Sheet Metal Forming (ISMF), a gradually prominent technique in metal forming, facilitates the production of small batches and prototype products by utilizing CNC machine-controlled tool motion. Metal forming is significant in diverse industries, including automotive, aerospace, manufacturing, and construction. Conventional metal forming methods encounter limitations in flexibility, cost-effectiveness, and productivity. The recent ISMF technology presents promising solutions to overcome these challenges. Lightweight alloys such as magnesium, titanium, and aluminium face formability limitations at room temperature, driving the demand for advanced forming technology. This paper delves into various manufacturing aspects and applications of ISMF in fields such as biomedical implants, automotive bodies in white manufacturing, aerospace, nuclear reactors, and defence. The study considers the impact of variables such as forming path, forming tool, and forming geometry on surface quality, process formability, and geometry accuracy. Furthermore, the paper explores recent advancements in incremental forming technology, including water jet ISMF, laser jet ISMF, ultrasonic-assisted ISMF, and electrically assisted ISMF. By synthesizing information from the past few years of published research, this work provides an overview of the expanding applications of ISMF and its evolving role in shaping various industries. The insights derived from this research aim to empower engineers and manufacturers to make informed decisions regarding implementing ISMF in their respective fields. Ultimately, this paper inspires researchers by highlighting current implementations in forming techniques and the significant contributions made in Single Point Incremental Forming (SPIF).