1. There is a revolutionary new process for shaping sheetmetal. Once a digital file is created, a specialized machine forces a powerful stylus into a metal sheet, creating a precisely contoured metal panel. This process has very few limitations.

By Ron Covell Photography Courtesy of Saltworks 3D Solutions

here is a new process for forming sheetmetal panels that we believe will soon gain traction in the specialty car market. This process, known as Digital Sheet Forming, utilizes a powerful computerized machine that presses a moving stylus against a sheet of metal backed by a urethane pad. The stylus starts by pushing against the outermost profile of the part and progressively moves inward with each pass, spiraling toward the center of the panel.

The machine can shape various types of metal, including aluminum up to 10-gauge thickness and steel up to 14-gauge. Its maximum panel size is 47×63 inches, and it can form to a depth of 15.7 inches. Larger parts can be formed in sections and subsequently joined by welding.

The digital file needed to operate the machine can be created using CAD software, or it’s possible to scan an existing part and either make an exact duplicate or modify the file as necessary for the specific application.

Saltworks 3D Solutions, located near Sarasota, Florida, is an early adopter of this technology within the custom auto industry. They purchased two Figur GT15 machines from Desktop Metal, based in Burlington, Massachusetts. They have been using these machine for over a year, and as they explore the capabilities they are proving to be a valuable addition to their metal shaping arsenal.

The resolution and accuracy of the shaping are excellent. The panels are often ready for use as soon as they come off the machine, although some handwork may be required in certain situations.

The photos showcase several parts being produced in a variety of shapes. Since the machine’s forming envelope is quite large, it often makes sense to form multiple parts during each operation. Generally, a considerable amount of metal is needed to support the shape being created, and any excess is trimmed away after the forming process is complete.

Due to the cost, not many shops will likely purchase these machines, but you can contact Saltworks 3D Solutions for a quote on any panels you may need.

3. A series of small dots have been placed on this panel to aid the scanning process.

5. The front fender for this International Scout has been digitized, with nodes defined at key points. These nodes can be moved in any direction to reshape the part as needed.

7. Shaping begins at the perimeter of the part, making concentric passes that go deeper while moving toward the center.

9. Here’s the interior of the completed section at full depth. The surface finish is outstanding.

11. Since the cavity inside the machine is quite large, it often makes sense to form two components at once. Here, two fender tips have been joined together back-to-back. Once the metal is formed, the individual parts will be removed from the supporting metal.

13. Here’s a shot of the inside of the two fender tips after completing the forming. This forming took about one hour.

15. The software operating on the Figur machine is highly sophisticated. It is intended to shape the parts with maximum speed while minimizing the reduction in material thickness.

17. The forming is approaching full depth here.

19. Nearly any shape that can be designed in CAD can be formed with this technology.