In one embodiment, the method includes providing a double sheet metal element including the two sheet metal end sections; and creating a connecting section along the connecting line. The creation of the connecting section includes introducing a first depression into the double sheet metal element, and creating a first folded section of the double sheet metal element. The method further includes orienting the connecting section relative to an extension plane of the double sheet metal element so that the connecting section extends perpendicularly to the extension plane.

A die assembly for use in a stamping press is provided. The die assembly includes a first die plate, a first curved die stiffener, and a first die shoe. The first die plate may be configured to form at least a portion of material into a desired configuration. The first curved die stiffener may be affixed to the first die plate on a first curved side of the first curved die stiffener. The first die shoe may be affixed to a second side of the first curved die stiffener. The first die shoe may be operatively configured to be mounted on a first press base.

A die assembly for use in a stamping press is provided. The die assembly includes a first die plate, a first curved die stiffener, and a first die shoe. The first die plate may be configured to form at least a portion of material into a desired configuration. The first curved die stiffener may be affixed to the first die plate on a first curved side of the first curved die stiffener. The first die shoe may be affixed to a second side of the first curved die stiffener. The first die shoe may be operatively configured to be mounted on a first press base.

A bending device for forming a corrugation in a metal sheet, the bending device having a frame, a die having two die elements, each having a concave half-impression, mounted able to slide on the frame; a punch having a head able to engage inside the impression of the die so as to press the metal sheet; and two side clamps mounted sliding and able to move vertically with respect to the lower frame so as to clamp the metal sheet against the bearing surfaces of the die elements. During the displacement of the punch into its bending position, the metal sheet transmits a traction force to the die elements and to the side clamps so as to displace them into their near position.

A bending device for forming a corrugation in a metal sheet, the bending device having a frame, a die having two die elements, each having a concave half-impression, mounted able to slide on the frame; a punch having a head able to engage inside the impression of the die so as to press the metal sheet; and two side clamps mounted sliding and able to move vertically with respect to the lower frame so as to clamp the metal sheet against the bearing surfaces of the die elements. During the displacement of the punch into its bending position, the metal sheet transmits a traction force to the die elements and to the side clamps so as to displace them into their near position.

A heat sink having a base and a projecting portion that extends from the base is manufactured by cold pressing a metal component. In the first process, a preparatory compact is formed by pressing the metal component with a first die including a first die block and a first punch. The preparatory compact has a depression on a surface of the metal component that faces the first punch and a protrusion on a surface of the metal component that faces the first die block. In the second process, by pressing the preparatory compact with the second die including a second punch and a second die block, the depression is crushed and the protrusion is pushed out toward the back of the hole of the second die block to form the projecting portion.

A heat sink having a base and a projecting portion that extends from the base is manufactured by cold pressing a metal component. In the first process, a preparatory compact is formed by pressing the metal component with a first die including a first die block and a first punch. The preparatory compact has a depression on a surface of the metal component that faces the first punch and a protrusion on a surface of the metal component that faces the first die block. In the second process, by pressing the preparatory compact with the second die including a second punch and a second die block, the depression is crushed and the protrusion is pushed out toward the back of the hole of the second die block to form the projecting portion.

An apparatus for making one or more registering contour features in a workpiece. At least some of the registering contour features have an outer annular rim and basin-shaped portion there within. One embodiment has: (i) one or more first tools, each tool being adapted to form the outer annular rim in one or more registering contour features; and (ii) one or more second tools for forming in cooperation with the first set of insert tools one or more of the basin-shaped portions that lie within the outer annular rims, thereby forming a set of one or more registering contour features in the workpiece so that workpieces in a stack are separated to facilitate subsequent handling by removing an uppermost workpiece from the stack.

An apparatus for making one or more registering contour features in a workpiece. At least some of the registering contour features have an outer annular rim and basin-shaped portion there within. One embodiment has: (i) one or more first tools, each tool being adapted to form the outer annular rim in one or more registering contour features; and (ii) one or more second tools for forming in cooperation with the first set of insert tools one or more of the basin-shaped portions that lie within the outer annular rims, thereby forming a set of one or more registering contour features in the workpiece so that workpieces in a stack are separated to facilitate subsequent handling by removing an uppermost workpiece from the stack.

Apparatus and methods for forming three dimensional structures from a sheet of material of a desired medium are described. Examples described include an apparatus for folding a sheet of material to create a folded structure, the apparatus having a first and second array of creasing elements, and at least one actuator for causing relative movement of the first and second array of creasing elements from a first position to a second position.