Some recent developments in two- and three-dimensional laser forming for 'macro' and 'micro' applications

Laser forming (LF) is an emerging laser process with potential for use in line bending or spatial forming of metal components and in the precise adjustment of novel miniature on-board actuators. The process is achieved by introducing thermal stresses into a work-piece by controlled irradiation with a focused laser beam. Unlike mechanical forming, there is no spring-back effect. A number of mechanisms have been identified to explain the thermo-mechanical behaviour in LF, accounting for various part geometries, laser process conditions and the complex interaction of many thermal and mechanical factors. Although these interactions are not yet fully understood, with increased knowledge of the process (in terms of theoretical models and control strategies) and the continued development of adaptive and/or predictive LF systems, the process offers significant potential value to industry. This review describes a number of recent developments and new techniques in two- and three-dimensional LF, for both macro- and micro-scale applications, and gives suggestions on the current industrial promise of the process. Macro-scale applications include rapid prototyping in industries that have relied on using expensive stamping dies and presses for design evaluations, while micro-scale applications already include the precision alignment of components during product assembly.