A folding device for bending a workpiece made of flat material. The folding device includes a machine frame having a flat mounting surface, at which a clamping cheek is arranged, which can be moved relative to the mounting surface. The clamping cheek clamps a workpiece which is positioned on the mounting surface at a specified or specifiable mounting position, to the machine frame. A bending means, of at least one bending tool can be moved relative to the mounting surface so that the clamped workpiece can be bent around a certain bending angle, is furthermore arranged at the folding device. A machine controller is coupled to a cutting tool drive of a cutting tool for cutting the workpiece and which for performing a cutting process for severing a workpiece which is smaller than a distance between the start position and the end position with respect to the bending axis.

A folding device for bending a workpiece made of flat material. The folding device includes a machine frame having a flat mounting surface, at which a clamping cheek is arranged, which can be moved relative to the mounting surface. The clamping cheek clamps a workpiece which is positioned on the mounting surface at a specified or specifiable mounting position, to the machine frame. A bending means, of at least one bending tool can be moved relative to the mounting surface so that the clamped workpiece can be bent around a certain bending angle, is furthermore arranged at the folding device. A machine controller is coupled to a cutting tool drive of a cutting tool for cutting the workpiece and which for performing a cutting process for severing a workpiece which is smaller than a distance between the start position and the end position with respect to the bending axis.

A flat routing material includes a flat conductive material and an insulating coating covering the conductive material. The routing material includes a bent portion as a part bending in an edgewise direction at a predetermined angle or more, and one or more folds extending toward the outer peripheral side of the bent portion are provided on at least the inner peripheral side of the bent portion. The folds are manufactured by press working.

A method of manufacturing a multi-sided or otherwise relatively three-dimensional formed structure for, e.g., an aerospace vehicle. A relatively planar base structure is constructed using a first construction technique. Features (e.g., ribs) are incorporated into the base structure using a second construction technique (e.g., additive or subtractive manufacturing) to create an intermediate structure. The intermediate structure is folded along fold-lines or otherwise physically formed to create the formed structure, such that some of the features are located within an internal space defined by the formed structure. Joints between the sides of the formed structure are welded, fastened, or otherwise secured. Separately constructed additional elements (e.g., bulkheads) may be incorporated into the structure. A closeout element may be added to the formed structure to further define and close the internal space. Throughout the process, the structures, features, and elements may be refined to desired tolerances.

The bending machine (100) has an upper beam (211) and a lower beam (212), each of the beams (211, 212) having a clamping element extending therefrom adapted for clamping an elongated flat sheet metal workpiece (218) with a portion extending from the machine in cantilever fashion. Bending tool carriers (221, 222) having a bending tool (223, 224) extending therefrom are movable relative to the beams so that the bending tool (223, 224) can extend and pivot to form an elongated bend in the workpiece (218). A plurality of wedges (251, 252) are selectively extendable between the beams (211, 212) and the carriers (221, 222) to provide uniform depth of the bend in the workpiece (218) along the length of the bend, the depth of extension being adjustable with ball screws (261, 262) attached to synchro or servomotors (265, 266).

The bending machine (100) has an upper beam (211) and a lower beam (212), each of the beams (211, 212) having a clamping element extending therefrom adapted for clamping an elongated flat sheet metal workpiece (218) with a portion extending from the machine in cantilever fashion. Bending tool carriers (221, 222) having a bending tool (223, 224) extending therefrom are movable relative to the beams so that the bending tool (223, 224) can extend and pivot to form an elongated bend in the workpiece (218). A plurality of wedges (251, 252) are selectively extendable between the beams (211, 212) and the carriers (221, 222) to provide uniform depth of the bend in the workpiece (218) along the length of the bend, the depth of extension being adjustable with ball screws (261, 262) attached to synchro or servomotors (265, 266).

Presented are metalworking systems for forming metallic workpieces, methods for making such workpieces and methods for operating such systems, and battery cell tabs bent by a multistage plunger press. A metalworking system includes a plunger fixture that mounts adjacent metallic workpieces, and a plunger head movably mounted to the plunger fixture to move between activated and deactivated positions. A first row of plunger fingers is mounted to the plunger head and moves in one direction to press against and bend one metallic workpiece a predefined bend angle. Likewise, a second row of plunger fingers is mounted to the plunger head and moves in an opposite direction to press against and bend another metallic workpiece another predefined bend angle. The plunger head then moves to the activated position, in tandem with the plunger fingers bending the metallic workpieces, to cause the plunger fingers to bend the workpieces additional respective bend angles.

Presented are metalworking systems for forming metallic workpieces, methods for making such workpieces and methods for operating such systems, and battery cell tabs bent by a multistage plunger press. A metalworking system includes a plunger fixture that mounts adjacent metallic workpieces, and a plunger head movably mounted to the plunger fixture to move between activated and deactivated positions. A first row of plunger fingers is mounted to the plunger head and moves in one direction to press against and bend one metallic workpiece a predefined bend angle. Likewise, a second row of plunger fingers is mounted to the plunger head and moves in an opposite direction to press against and bend another metallic workpiece another predefined bend angle. The plunger head then moves to the activated position, in tandem with the plunger fingers bending the metallic workpieces, to cause the plunger fingers to bend the workpieces additional respective bend angles.

Presented are metalworking systems for forming metallic workpieces, methods for making/operating such systems, and battery packs with cell terminals bent by a two-stage plunger press. A metalworking system includes a first plunger with a plunger cavity extending through the first plunger's body, and one or more die cavities recessed into the first plunger's contact face. The die cavity includes one surface that contacts and bends a first workpiece a first angle, and another surface that contacts and bends a second workpiece a second angle. A second plunger includes one or more die cavities recessed into the second plunger's contact face. This die cavity includes one surface that contacts and bends the first workpiece a third angle, and another surface that contacts and bends the second workpiece a fourth angle. The second plunger passes through the plunger cavity such that the first and second plungers bend the metallic workpieces in tandem.

A jig includes a base and one or more movable blocks. The base has an upper surface, which is configured to receive a substrate shaped as a flattened polyhedron having multiple facets. The one or more movable blocks are configured to move on the base so as to fold respective ones of the multiple facets, and to hold the substrate in a folded three-dimensional configuration.