A multi-stage incremental sheet forming system includes a forming tool, and at least one control unit in communication with the forming tool. The at least one control unit is configured to determine a convex hull of a target structure to be formed by the forming tool. The at least one control unit is further configured to operate the forming tool according to a first tool path in relation to an initial structure to form an intermediate structure having a shape based on the convex hull of the target structure. The at least one control unit is further configured to operate the forming tool according to a second tool path in relation to the intermediate structure to form one or more inward features into the intermediate structure to form the target structure.

A high-strength metal plate for vehicles is provided. The plate includes oval embossments that protrude from the plate. The embossments include first embossments that have a longer axis oriented in a first direction and second embossments that have a longer axis in a second direction. Bridges are provided on portions of the flat plate between the embossments and flat portions are provided on the flat plate to be surrounded by the first and second embossments while the bridges separate the flat portions from each other.

A high-strength metal plate for vehicles is provided. The plate includes oval embossments that protrude from the plate. The embossments include first embossments that have a longer axis oriented in a first direction and second embossments that have a longer axis in a second direction. Bridges are provided on portions of the flat plate between the embossments and flat portions are provided on the flat plate to be surrounded by the first and second embossments while the bridges separate the flat portions from each other.

A slope-matched stylus (SMS) tool for Incremental Sheet Forming (ISF) of a sheet includes a shaft connected to a stylus body and to a multi-axis drive mechanism. The stylus body has a conical or generally frustoconical form which includes a tool surface defining one or more corresponding tool wall angles. The tool wall angle range matches one or more part wall angles of a part formed via the ISF process, such that a flat line of contact exists between the stylus body and sheet. The tool and part wall angles are complementary. A system includes the tool and drive mechanism. A method includes securing the sheet to a fixture, connecting the tool to the drive mechanism, and progressively pressing a tool surface of the stylus body into or against the sheet using the drive mechanism, controlling the latter to ensure a flat line of contact is provided between the stylus body and sheet.

A tool for use during double sided incremental forming of a workpiece. The tool includes a sleeve with a hollow interior space. A contact member is positioned within the hollow interior space of the sleeve. The contact member is sized with a working tip positioned outward beyond the sleeve to contact against a workpiece. A mount is positioned on the opposing end of the sleeve and configured to connect to a tool holder. The tool is configured to provide for translational and/or rotational movement of the contact member. The axial and rotational movement provides for the working tip to remain in contact with the workpiece during the forming process.

Flanges formed on sheet metal parts to increase the part stiffness or create mating surface for further assembly are created in an incremental sheet forming process using forming tool and supporting tool that move along a specified tool path so as to gradually deform a peripherally-clamped sheet metal work piece into the desired geometry. With two universal tools moving along the designed toolpath on the both sides of the part, the process is very flexible. Process time is can also be reduced by utilizing an accumulative double-sided incremental hole-flanging strategy, in which the flange is formed in only one step.

A structured multi-phase composite which include a metal phase, and a low stiffness, high thermal conductivity phase or encapsulated phase change material, that are arranged to create a composite having high thermal conductivity, having reduced/controlled stiffness, and a low CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured multi-phase composite is useful for use in structures such as, but not limited to, high speed engine ducts, exhaust-impinged structures, heat exchangers, electrical boxes, heat sinks, and heat spreaders.

A structured multi-phase composite which include a metal phase, and a low stiffness, high thermal conductivity phase or encapsulated phase change material, that are arranged to create a composite having high thermal conductivity, having reduced/controlled stiffness, and a low CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured multi-phase composite is useful for use in structures such as, but not limited to, high speed engine ducts, exhaust-impinged structures, heat exchangers, electrical boxes, heat sinks, and heat spreaders.

A single piece stent construction having a plurality of commissure posts, each of which extends upwardly from a solid ring along a bend line and generally along a central longitudinal axis of the stent.

A single piece stent construction having a plurality of commissure posts, each of which extends upwardly from a solid ring along a bend line and generally along a central longitudinal axis of the stent.