A structural component for a vehicle may include an extrusion that is extruded into a first state and then expanded into a second state. The extrusion in the first state has a reduced size relative to a desired final size. The extrusion in the first state is placed within a die that defines the desired final size. Pressurized water is distributed within internal cells of the extrusion in the first state such that the walls defining the internal cells are expanded into engagement with the surface of the die, thereby creating surface features or sealing interfaces with tight tolerances. The relative shape of the die and the extrusion in the first state defines an open space herebetween, into which the extrusion may expand to define the final shape. Some of the internal cells may be plugged such that they are not provided with pressurized water.

One embodiment includes a structural panel for an aerospace vehicle, including a single sheet of material, the material having a first raised pattern on a first side, and a second raised pattern on a reverse side, wherein a repeating portion of the first raised pattern is substantially identical in size and shape to a repeating portion of the second raised pattern, and is rotated at an angle θ to the first raised pattern.

One embodiment includes a structural panel for an aerospace vehicle, including a single sheet of material, the material having a first raised pattern on a first side, and a second raised pattern on a reverse side, wherein a repeating portion of the first raised pattern is substantially identical in size and shape to a repeating portion of the second raised pattern, and is rotated at an angle θ to the first raised pattern.

A Z-shaped attachment element for use in building construction is disclosed. The Z-shaped attachment element is made from a single piece of sheet metal that is first cut and then bent to form the Z-shaped cross-sectional profile. The Z-shaped attachment element comprises: an elongated upper flange; an elongated lower flange, wherein the upper and lower flanges are spaced apart and substantially parallel to each other; an elongated middle web section between, and connected to, the upper and lower flanges along respective upper and lower lengthwise bends (wherein the middle web section is diagonal in relation to the position of the upper and lower flanges, thereby defining a generally Z-shaped cross-sectional profile); and a plurality of notches formed along the lower lengthwise bend and into the lower flange and the adjoining middle web section, but not into the upper bend or the upper flange, of the Z-shaped sheet metal attachment element.

A Z-shaped attachment element for use in building construction is disclosed. The Z-shaped attachment element is made from a single piece of sheet metal that is first cut and then bent to form the Z-shaped cross-sectional profile. The Z-shaped attachment element comprises: an elongated upper flange; an elongated lower flange, wherein the upper and lower flanges are spaced apart and substantially parallel to each other; an elongated middle web section between, and connected to, the upper and lower flanges along respective upper and lower lengthwise bends (wherein the middle web section is diagonal in relation to the position of the upper and lower flanges, thereby defining a generally Z-shaped cross-sectional profile); and a plurality of notches formed along the lower lengthwise bend and into the lower flange and the adjoining middle web section, but not into the upper bend or the upper flange, of the Z-shaped sheet metal attachment element.

A component of a vehicle structure is obtained by a hot forming operation on a hybrid panel having a sheet element of light alloy and a sheet of plastic material. The hybrid panel is hot formed by pressing it against a forming surface of a mould element by a pressurized gas or by a second mould element. Following this operation, the hybrid panel assumes a configuration corresponding to the forming surface, whereas the light alloy sheet element and the plastic material sheet constituting the hybrid panel adhere to each other following softening by heat of the plastic material. Before the hot forming step, a surface of said light alloy sheet element which must contact the plastic material sheet is subjected to a roughening treatment, thereby defining surface asperities between which the plastic material of the plastic material sheet is inserted when it is softened by heat.

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 processing device processes a frame-shaped workpiece which extends in a prescribed extension direction, and includes, integrally, a plate-shaped web surface portion, a plate-shaped first flange portion that bends and extends from one end of the web surface portion, and a plate-shaped second flange portion which bends from the other end of the web surface portion and extends in the opposite direction to the first flange portion. The processing device includes a shaping device which conveys the workpiece in the extension direction, and an exit side pinch roll device provided further downstream, in the workpiece conveying flow direction, than the shaping device. The exit side pinch roll device includes a first roll which presses a central region of an upper surface side of the web surface portion, and a second roll which presses a central region of a lower surface side of the web surface portion.

A processing device processes a frame-shaped workpiece which extends in a prescribed extension direction, and includes, integrally, a plate-shaped web surface portion, a plate-shaped first flange portion that bends and extends from one end of the web surface portion, and a plate-shaped second flange portion which bends from the other end of the web surface portion and extends in the opposite direction to the first flange portion. The processing device includes a shaping device which conveys the workpiece in the extension direction, and an exit side pinch roll device provided further downstream, in the workpiece conveying flow direction, than the shaping device. The exit side pinch roll device includes a first roll which presses a central region of an upper surface side of the web surface portion, and a second roll which presses a central region of a lower surface side of the web surface portion.