APPARATUS AND METHOD FOR INCREMENTALLY FORMING A WORKPIECE

Abstract

Incremental sheet forming system employing resilient tooling. The present invention relates to a double-sided incremental sheet forming apparatus and a method for incrementally forming sheet materials, such as sheet metal, using opposing primary and secondary forming tool assemblies and a sheet feed assembly. The primary forming tool assembly includes a rigid tool, and the secondary forming tool assembly includes a compressible and resilient support layer having a cylindrical or flat configuration. The sheet feed assembly positions the sheet material between the two forming tools. The rigid tool applies force to one surface of the sheet material, while the resilient support tool applies opposing force to the opposite surface of the workpiece, while supporting the workpiece.This double-sided process locates the forces in the sheet material so that stresses are advantageously controlled to produce precisely formed asymmetrical shapes without the need for expensive dies. The use of a rigid tool with an opposing resilient support tool, both with independent linear motion, also avoids potential wrinkling and tearing of the resulting workpiece and allows for the forming of various highly detailed asymmetrical products.

Description

1 / 55 APPARATUS AND METHOD FOR INCREMENTALLY FORMING A WORKPIECE FIELD OF THE INVENTION

[001] The present invention relates to an apparatus and method for incrementally shaping sheet materials, such as sheet metal. CROSS-REFERENCE TO RELATED ORDERS

[002] This application claims priority with respect to Provisional Application Number 62 / 844,177, filed on May 7, 2019, and claims priority with respect to Provisional Application Number 63 / 006,802, filed on April 8, 2020, each of which is incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION

[003] Various methods for shaping sheet materials (typically metal) into complex shapes have been developed over the years. Sheet forming technologies exist in a wide range of industries and apply to a variety of metals and plastics. Typical high-volume production of sheet metal parts utilizes stamping technology. Stamping requires the use of two rigid dies that are machined with a high degree of precision. A sheet of material (i.e., workpiece) is pressed between the two dies to shape the material into the desired configuration, as established by the dies.

[004] Alternative stamping methods have been used to shape sheet material without the need for a complete two-die assembly. Instead, a single rigid die is positioned on one side of a sheet of material. Force is then applied to the other side of the material using a support material or by fluid pressure, thus shaping the material into the desired configuration as determined by the single die. Although the use of one or two dies in technologies of Petition 870250003926, dated 17 / 01 / 2025, page 13 / 160 2 / 55 While sheet metal forming has advanced over the years, the engineering, manufacturing, and maintenance expenses of any die discourage low-volume production of metal parts. In addition to the manufacturing cost of the die(s), the time required to produce the die(s) further discourages the use of small volumes and prototypes.

[005] Another technique for shaping sheet materials is called Incremental Sheet Forming (ISF), in which, at any given time, only a small portion of the sheet metal is actually being incrementally shaped by the forming process. Emmens et al., The Technology of Incremental Sheet Forming - A brief review of the history, Journal of Materials Processing Technology (2010) and Jeswiet et al., Asymmetric Single Point Incremental Forming of Sheet Metal. CIRP Annals - Manufacturing Technology 54(2): 88-114 (December 2005).

[006] The incremental sheet metal forming system of the present invention not only provides flexibility over previous systems by removing long lead times and the need for expensive dies to form complex sheet metal parts, but also localizes the forming forces on the workpiece, so as to precisely and locally control the stress that occurs during the forming of the sheet material. DESCRIPTION OF THE RELATED TECHNIQUE

[007] Single Point Incremental Forming (SPIF), a variant of ISF, is a method for forming one side of sheet material (typically metal) without the need for any dies. The preceding examples of SPIF incorporate several different implementations. One of the simplest implementations of SPIF comprises a rigid clamping mechanism to constrain a sheet metal workpiece along all four of its outer edges, while a single Petition 870250003926, dated 17 / 01 / 2025, page 14 / 160 3 / 55 The forming tool or roller punch is located on one side of the sheet metal. Following the designated paths, the tool presses the fixed sheet metal so as to form the desired shape. Emmens et al., supra, section 2.2 and Fig. 4, with reference to Iseki et al., Flexible and Incremental Sheet Metal Forming Using a Spherical Roller; Proc. 40th JJCYP (1989 pages 41-44).

[008] Two-Point Incremental Forming (TPIF), also known as double-sided incremental forming, is another variation of ISF in which the sheet material is generally clamped at its outer edges and force is applied from each side of the sheet material. An example of a double-sided forming method uses two rigid, opposing forming tools that move along each side of a workpiece to apply force and counterforce. In US Patent No. 8,302,442, the sheet clamping assembly 20 (clamp assembly) supports the workpiece 12, while the forming tools 32 and 32 exert force on both sides of the workpiece 12. The tools may be located directly opposite each other or offset relative to each other. Furthermore, each forming tool may be mounted on a 6-axis platform, allowing movement in 3 translational directions and 3 rotational axes.(See also US Patents Numbers 8,783,078; 8,773,143 and 8,322,176). Although exerting somewhat better control over the workpiece than SPIF techniques, a loss of forming speed and an additional level of complexity and precision are required to coordinate the paths of each opposing forming tool by the controller 26 and form the workpiece 12 into the desired configuration. However, the difficulty remains in precisely controlling the positioning of the opposing tool during the forming process, leading to defects such as wrinkles and tearing in the resulting workpiece configuration. Petition 870250003926, dated 17 / 01 / 2025, page 15 / 160 4 / 55

[009] In another example of double-sided forming, a rigid tool is located on one side of a workpiece and, instead of a second rigid tool on the other side, a single die is located on the other side. As seen in patent JP 10-314855 (Ueno et al.), die 3 is fixed in position and tool 5 presses workpiece 4 towards die 3. Although tool 5 is relatively universal in this example, die 3 must be specifically manufactured for each different desired configuration, thus retaining the challenges associated with the manufacturing time and cost of using any die.

[0010] A further example of a double-sided forming method is seen in US Patent Number 7,536,892. Clamp 1 is arranged to fix the circumference of workpiece W. Die 2 and tool 4 advance sequentially toward each other to press workpiece W into the shape corresponding to die 2. The presence of die 2, however, retains the disadvantageously long duration time and costs inherent in the use of any die.

[0011] Another example of a double-sided forming method is seen in US Patent Number 6,151,938. The press 2, comprising a plurality of punching elements, is located on one side of the raw material 3, while the elastomer 4 is positioned on the other side and is in frontal contact with the raw material 3. The control unit 5 moves the punching elements only along one axis towards their intended positions, thus applying force to the raw material 3. The elastomer 4 generates a repulsive force that supports the raw material 3. In the case of a long formed product, the raw material 3 can be moved longitudinally, whereby the forming process is carried out step by step along the length of the raw material. The process is also mechanically complex due to the use of many punching elements that form the material. Petition 870250003926, dated 17 / 01 / 2025, page 16 / 160 5 / 55 gross. This punching process is also limited to the production of relatively simple shapes.

[0012] In another example, US Patent Number 3,342,051 describes a double-sided rotating ISF device and method in which the raw material 6 is fully fixed between two clamping rings 3 and 4, which slide freely on guide pins 5, in the direction of an axis perpendicular to the plane of the raw material 6. In turn, the guide pins 5 are fixed to the support plate 1 which rotates with the turntable V (not shown). The deformation tool 7 or a rotating sphere 8 is positioned on one side of the raw material 6 and the resilient material 2 is positioned on the opposite side and fixed to the support material 1. As the raw material 6 rotates with the resilient material 2 and the turntable V, the deformation tool 7 is fed transversely along an axis, traversing from the outer edge of the raw material 6 towards its center in spiral revolutions.The deformation tool 7 is placed against the raw material 6, along an axis perpendicular to the plane of the raw material 6, so as to deform the raw material 6 into the desired configuration, always having circular cross-sections. Since the deformation tool 7 and the rotary table V, respectively, move only in two linear axes and one axis of rotation, this forming method is disadvantageously limited to producing a figure of revolution containing only circular cross-sectional shapes. The device Ό51, therefore, is not capable of independent linear movement in 3 axes (i.e., X, Y, and Z axes) nor of forming asymmetrical shapes, as can be obtained by the present invention.

[0013] In contrast, the present invention is preferably directed to apparatus and methods for incremental forming of double-sided sheets, without the use of specifically constructed dies, but rather with unique tools and movements that can be universally applied to form a variety of Petition 870250003926, dated 17 / 01 / 2025, page 17 / 160 6 / 55 forms with a minimum proportion of strength.

[0014] The present invention preferably includes a primary rigid tool and a secondary tool having a compressible and resilient layer of material. A workpiece consisting of a sheet material is positioned between the opposing tools. The primary rigid tool applies force to one surface of the sheet material, while the secondary resilient tool applies a controlled counterforce to the opposite surface of the sheet material. This double-sided process localizes the forces on the sheet material to a contact area on the workpiece, between the opposing tools (rather than the widely applied forces and resulting overall stresses exerted on the entire sheet material by using only a rigid tool on one side of the sheet material).By locating the forces in the sheet material at the contact area, the stresses and, ultimately, the forming are also located and controlled more precisely and accurately, and in accordance with the present invention, when compared to single-point incremental sheet forming.

[0015] Furthermore, by using a primary rigid tool positioned on one side of a workpiece in conjunction with an opposing secondary resilient tool, both with independent linear motion (instead of using two opposing rigid tools as found in many previous double-sided techniques), the present invention avoids the potential wrinkling and tearing of the resulting workpiece. The single double-sided forming process and apparatus of the present invention, therefore, produces numerous asymmetric and more accurately formed products by a simpler and better controlled process and ultimately uses less energy than single-sided or double-sided incremental sheet forming methods. SUMMARY

[0016] According to one aspect of the present invention, it is described Petition 870250003926, dated 17 / 01 / 2025, page 18 / 160 7 / 55 an apparatus for incrementally forming a workpiece (see, for example, Figures 1A-C, 2A-C, 3A-C, 4A-B and 5). The workpiece has first and second surfaces that are opposite and parallel, a work area for forming the workpiece, and defines a reference plane that is parallel to the surfaces. The apparatus includes a primary forming tool assembly positioned adjacent to and facing the first surface of the workpiece, and capable of movement in and out of engagement with the workpiece in a direction perpendicular to the reference plane and in all directions parallel to the reference plane. The primary forming tool assembly may have a forming tip for forming the workpiece. The tip is positioned towards the first surface of the workpiece.The apparatus also includes a secondary forming tool assembly having a resilient surface portion or material layer facing the second surface of the workpiece, and capable of movement into and out of engagement with the workpiece in a direction perpendicular to the reference plane.

[0017] One or both of the workpieces and the primary forming tool assembly move relative to each other, being able to be moved to position the primary forming tool assembly within the work area; and exert force on the first surface of the workpiece in the direction perpendicular to the reference plane, while the resilient secondary forming tool assembly is engaged in the workpiece and exerts a counterforce to support the second surface of the workpiece, so that a force is exerted on the workpiece during forming.

[0018] According to one aspect of the invention, the above apparatus may also include a sheet feed assembly (see, for example, Figures 1A-C). The sheet feed assembly Petition 870250003926, dated 17 / 01 / 2025, p. 19 / 160 8 / 55 includes a sheet feed roller assembly having at least one set of rollers that contact the respective first and second surfaces of the workpiece. The roller assembly is capable of moving the workpiece in a direction parallel to the reference plane.

[0019] Alternatively, the sheet feed assembly above includes a sheet feed belt assembly having at least one continuous belt that encircles and contacts a set of rotating rollers (see, for example, Figures 2A-C). The belt is positioned in contact relation to the first or second surfaces of the workpiece and is capable of moving the workpiece in a direction parallel to the reference plane.

[0020] Instead, the sheet feed assembly above may include a sheet clamping assembly having a rigid structure and a retainer capable of securely holding the workpiece between them (see, for example, Figures 3A-C, 4A-C and 5). The sheet clamping assembly defines an opening for access to the workpiece by the primary forming tool assembly on the first surface of the workpiece and by the secondary forming tool assembly on the second surface of the workpiece.

[0021] According to another aspect of the invention, an apparatus is described for forming a workpiece from sheet material. This workpiece has first and second surfaces that are opposite and parallel and define a reference plane that is parallel to the first and second surfaces of the workpiece. The apparatus includes a sheet feed assembly capable of moving the workpiece in a direction parallel to the reference plane. The apparatus also includes a primary forming tool assembly, positioned facing the first surface of the workpiece and capable of movement in a first direction perpendicular to the reference plane and in a second direction that is parallel to the reference plane and Petition 870250003926, dated 17 / 01 / 2025, page 20 / 160 9 / 55 perpendicular to the direction of movement of the workpiece by the sheet feed assembly.

[0022] The apparatus further includes a support roll tool assembly capable of movement in a direction perpendicular to the reference plane and having an elongated cylindrical configuration for rotating about its longitudinal axis which is positioned parallel to the second direction of movement of the primary forming tool assembly. The support roll tool consists of an inner core and an outer resilient layer attached to it, which is positioned facing the second surface of the workpiece. Alternatively, the support roll tool assembly may have an outer surface, a portion of which is compressible when a force is applied to it, but resiliently returning to its non-compressed configuration when the force is removed (see, for example, Figures 1A-C, 2A-C and 3A-C).

[0023] The primary forming tool assembly and the support roll tool assembly are capable of being in simultaneous contact with the respective first and second opposite surfaces of the workpiece, generally opposite to each other, whereby the primary forming tool assembly exerts force on the first surface of the workpiece to form the workpiece and the support roll tool assembly exerts a counterforce on the second surface of the workpiece while the workpiece is being formed, whereby the process creates a localized force on the workpiece.

[0024] According to another aspect of the invention, an apparatus is described for shaping a workpiece of sheet material into a predetermined configuration. The workpiece has first and second surfaces that are opposite and parallel and defines a reference plane that is parallel to the surfaces of the workpiece. The apparatus includes a roller tool assembly. Petition 870250003926, dated 17 / 01 / 2025, page 21 / 160 10 / 55 support capable of rotating around its longitudinal axis and having an inner core and an outer resilient layer fixed to it or a portion of the outer surface. Along its longitudinal axis, the support roller assembly faces the second surface of the workpiece and is parallel to the reference plane (see, for example, Figures 1A-C, 2A-C and 3AC).

[0025] The apparatus also includes a primary forming tool assembly, positioned adjacent to and facing the first surface of the workpiece. The primary forming tool assembly is capable of exerting a force on the first surface of the workpiece to form the workpiece locally, while moving in a first direction parallel to the longitudinal axis of the support roll assembly. The apparatus also includes a sheet clamping assembly having a rigid structure and a retainer capable of securely holding the workpiece in place. The sheet clamping assembly is positioned parallel to the reference plane and defines an opening for access to the workpiece by the primary forming tool assembly on the first surface of the workpiece and by the secondary forming tool assembly on the second surface of the workpiece.

[0026] The primary forming tool assembly and the support roll tool assembly are able to move in a direction perpendicular to the reference plane, so as to contact the respective first and second surfaces of the workpiece. As a result, the force exerted by the primary forming tool assembly on the first surface of the workpiece is compensated by a counterforce exerted on the second surface of the workpiece by the support roll tool assembly, thus supporting the workpiece in an area located on the primary forming tool while the workpiece undergoes forming. Petition 870250003926, dated 17 / 01 / 2025, page 22 / 160 11 / 55

[0027] According to a further aspect of the invention, another apparatus is described for incrementally shaping a workpiece (see, for example, Figures 1A-C, 2A-C, 3A-C, 4A-B and 5). The workpiece has first and second opposing surfaces positioned in an XY plane of a three-dimensional X, Y, Z coordinate system. The apparatus includes a primary forming tool assembly positioned adjacent to and facing the first surface of the workpiece. The apparatus also includes a secondary forming tool assembly having a rigid body and a compressible and resilient layer of material attached to it and positioned adjacent to and facing the second surface of the workpiece.

[0028] The workpiece, the primary forming tool assembly, and the secondary forming tool assembly are capable of moving independently in a predetermined sequence and pattern relative to each other along at least one of the X, Y, or Z axes of the coordinate system. The primary forming tool assembly and the workpiece are also capable of moving relative to each other along the X, Y, and Z axes. The secondary forming tool assembly is capable of movement along the Z-axis relative to the workpiece. As a result, the primary forming tool assembly is capable of exerting force on the first surface of the workpiece. The secondary forming tool assembly is also capable of exerting a counterforce along the Z-axis against the second surface of the workpiece, thus locally supporting the workpiece.During the forming process, the forming force is substantially localized in the area of ​​contact between the primary forming tool and the workpiece (see, for example, Figure 10).

[0029] According to another aspect of the invention, the above apparatus includes a control system capable of simultaneously coordinating Petition 870250003926, dated 17 / 01 / 2025, page 23 / 160 12 / 55 the respective movements of the workpiece, the primary forming tool assembly and the secondary forming tool assembly, in relation to each other. The coordinated movements of these components cause the primary forming tool assembly to follow a predetermined path along the first surface of the workpiece, while the secondary forming tool assembly simultaneously follows the same path along the second surface of the workpiece.

[0030] In another aspect of the invention, a method is described for incrementally forming a workpiece having at least one work area and having first and second opposite and parallel surfaces positioned in an XY plane of a three-dimensional orthogonal coordinate system X, Y, Z (see, for example, Figure 7). The method comprises providing an apparatus having a primary forming tool assembly positioned adjacent to and facing the first surface of the workpiece; and a supporting forming tool assembly having a compressible and resilient surface portion that is positioned adjacent to and facing the second surface of the workpiece. The workpiece, the primary forming tool assembly, and the supporting forming tool assembly are capable of moving independently in a predetermined sequence and pattern relative to each other.

[0031] The primary forming tool assembly is positioned relative to the workpiece to move simultaneously to a predetermined X, Y, Z coordinate, so as to be adjacent to the first surface of the workpiece within the work area. The supporting forming tool assembly is positioned relative to the workpiece to move simultaneously to a predetermined Z coordinate within the work area, so as to be in Petition 870250003926, dated 17 / 01 / 2025, p. 24 / 160 13 / 55 contact with the second surface of the workpiece and opposite to the position of the primary forming tool assembly. The primary forming tool assembly advances toward the workpiece in the Z direction, to a predetermined Z coordinate, so as to make contact with and exert a force on the first surface of the workpiece at a contact point within the work area. As a result, the workpiece conforms to a predetermined configuration and the resilient support forming tool assembly compresses to support the second surface of the workpiece while it is being formed.

[0032] The primary forming tool assembly moves relative to the workpiece in an XY plane (see, for example, Figure 7) along a predetermined coordinate assembly, thus following a predetermined path, along which the workpiece is consistently formed in the Z direction within the work area. The primary forming tool assembly retracts from the workpiece in the Z direction and repositions itself in an XY plane to a predetermined coordinate assembly adjacent to the first surface of the workpiece. The above steps can be repeated using sequentially progressive incremental values ​​for the Z coordinates, until the workpiece is fully formed within the work area.

[0033] In another aspect of the present invention, the apparatus of the above method further includes a control system having a controller assembly and a contactless or contactless sensor. With the sensor(s), the control assembly simultaneously measures the conformation ratio of the workpiece at specified positions along its forming path. The resulting measurements are compared to a predetermined conformation ratio of the workpiece at the same specified positions along the forming path. The Petition 870250003926, dated 17 / 01 / 2025, page 25 / 160 14 / 55 resulting comparative measurements are relayed to the control assembly. The control assembly then adjusts the position of at least one of the primary forming tool assemblies and the supporting forming tool assemblies, relative to the pre-programmed forming proportions required along the path, in order to form the workpiece into the predetermined shape.

[0034] Another aspect of the invention is directed to a method for incrementally forming a workpiece having at least first and second work areas that are separated from each other and having first and second surfaces opposite and parallel positioned in an XY plane of a three-dimensional orthogonal coordinate system X, Y, Z (see, for example, Figures 8A - B). The method comprises providing an apparatus having a primary forming tool assembly positioned adjacent to and facing the first surface of the workpiece and a supporting forming tool assembly having a compressible and resilient surface portion and being positioned adjacent to and facing the second surface of the workpiece.The workpiece, the primary forming tool assembly, and the support forming tool assembly are capable of moving independently, in a predetermined sequence and pattern relative to each other.

[0035] The primary forming tool assembly is positioned relative to the workpiece to move simultaneously to a predetermined X, Y, Z coordinate, so as to be adjacent to the first surface of the workpiece within the first work area. The resilient support forming tool assembly is positioned relative to the workpiece at a predetermined Z coordinate within the first work area, so as to be in contact with the second surface of the workpiece and opposite the position of the Petition 870250003926, dated 17 / 01 / 2025, page 26 / 160 15 / 55 Primary Forming Tool Assembly. The primary forming tool assembly advances toward the workpiece in the Z direction to a predetermined Z coordinate so as to make contact with and exert force on the first surface of the workpiece within the first work area at a point of contact.

[0036] As a result, the workpiece conforms to a predetermined configuration, and the resilient surface portion of the supporting forming tool assembly is compressed to support the second surface of the workpiece, resulting in localization on the workpiece while it is being formed. The primary forming tool assembly moves relative to the workpiece in an XY plane, along a predetermined coordinate assembly having substantially the same Z coordinate, thus following a predetermined path along which the workpiece is consistently formed in the Z direction, in the first work area. The primary forming tool assembly retracts from the workpiece in the Z direction and repositions itself in an XY plane in a predetermined coordinate assembly within the second work area adjacent to the first surface of the workpiece.

[0037] The primary forming tool assembly advances toward the workpiece in the Z direction, within the second work area to the same Z coordinate that was selected for the first work area, so as to make contact and exert a localized force on the first surface of the workpiece at a point of contact. As a result, the workpiece conforms to a predetermined configuration and the resilient surface portion of the secondary forming tool assembly is compressed so as to support the second surface of the workpiece while it is being formed. The primary forming tool assembly moves in Petition 870250003926, dated 17 / 01 / 2025, page 27 / 160 16 / 55 in relation to the workpiece, in an XY plane along a predetermined coordinate assembly that is substantially the same in the Z direction, thus following a predetermined path along which the workpiece is consistently formed in the Z direction in the second work area. The primary forming tool assembly retracts from the workpiece in the Z direction. The above steps can be repeated using sequentially progressive incremental values ​​for the Z coordinates until the workpiece is fully formed in each work area.

[0038] According to another aspect of the invention, a method is described for incrementally forming at least one work area of ​​a workpiece having initially a generally flat configuration and first and second opposite surfaces positioned in an XY plane of a three-dimensional orthogonal coordinate system X, Y, Z (see, for example, Figures 7 and 8). According to the method, a primary forming tool assembly is positioned adjacent to the first surface of the workpiece. The primary forming tool assembly has a tip capable of forming the workpiece when forcibly engaged with it, the tip having a hardness value that is greater than that of the workpiece.

[0039] A support roll tool assembly is positioned adjacent to the second surface of the workpiece. The support roll tool assembly can be moved in the Z direction. The support roll tool assembly still has a compressible and resilient outer surface portion, at least one support roll tool assembly, and the resilient outer surface portion is rotatable about a longitudinal axis that extends through the center of the support roll tool assembly. The support roll tool assembly advances toward the workpiece along the Z axis to contact and support the second surface of the workpiece. Petition 870250003926, dated 17 / 01 / 2025, page 28 / 160 17 / 55 workpiece.

[0040] The primary forming tool assembly advances along the Z-axis relative to the workpiece so that the tip engages the first surface of the workpiece and provides a predetermined proportion of forming force on it to form the workpiece. The position of the support roll tool assembly is maintained to provide sufficient reactive force on the second surface of the workpiece. The sufficiency of the reactive force is determined by the degree of compressibility and resilience of the outer surface portion of the support roll tool assembly.

[0041] The primary forming tool assembly is moved relative to the workpiece in the XY plane along a predetermined coordinate assembly having substantially the same Z coordinate, so as to follow a predetermined path along which the workpiece is consistently formed in the Z direction. The support roll tool assembly moves, in conjunction with the movement of the primary forming tool assembly, to remain substantially opposite the tip of the primary forming tool assembly with the workpiece between them, thus maintaining the force localized on the workpiece. The primary forming tool assembly and said support roll tool assembly retract from the workpiece.The steps above can be repeated successively within one or more additional work areas of the workpiece, until the workpiece is conformed to the final pre-programmed and predetermined configuration. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figures 1A - C represent a first embodiment (Embodiment 1) of the present ISF system having a sheet feed roller assembly for advancing a workpiece, a primary forming tool assembly and Petition 870250003926, dated 17 / 01 / 2025, page 29 / 160 18 / 55 a secondary forming tool assembly. In particular: Figure 1A represents an exemplary axonometric view of Modality 1; Figure 1B represents an exemplary front section view of Modality 1; and Figure 1C represents an exemplary side section view of Modality 1.

[0043] Figures 2A - C represent a second embodiment (Embodiment 2) of the present ISF system with a sheet feed belt assembly for advancing a workpiece, a primary forming tool assembly and a secondary forming tool assembly. In particular: Figure 2A represents an exemplary axonometric view of Modality 2; Figure 2B represents an exemplary front sectional view of Modality 2; and Figure 2C represents an exemplary side sectional view of Modality 2.

[0044] Figures 3A - C represent a third embodiment (Embodiment 3) of the present ISF system with a moving frame assembly for advancing a workpiece, a primary forming tool assembly and a secondary forming tool assembly. In particular: Figure 3A represents an exemplary axonometric view of Modality 3; Figure 3B represents an exemplary front sectional view of Modality 3; and Figure 3C represents an exemplary side sectional view of Modality 3.

[0045] Figures 4A and B represent a fourth embodiment (Effect 4) of the present ISF system with an assembly of Petition 870250003926, dated 17 / 01 / 2025, page 30 / 160 19 / 55 fixed structure for holding a workpiece, a primary forming tool assembly and a secondary forming tool assembly. In particular: Figure 4A represents an exemplary axonometric view of Modality 4; and Figure 4B represents an exemplary front cross-sectional view of Modality 4.

[0046] Figure 5 represents another exemplary axonometric view of Modality 4 as incorporated into a machine center.

[0047] Figures 6A - D represent front cross-sectional views, examples of a workpiece subjected to a sequence of incremental forming steps according to embodiments of the present invention.

[0048] Figure 7 is an exemplary top view of a workpiece being shaped according to embodiments of the present invention.

[0049] Figures 8A and B represent a method for forming multiple forming areas in a single workpiece that goes through a sequence of incremental forming steps according to embodiments of the present invention. In particular: Figure 8A is an exemplary top view of a workpiece being formed in various locations according to embodiments of the present invention; and Figure 8B represents an exemplary front cross-sectional view of a workpiece subjected to a sequence of multiple incremental forming steps according to embodiments of the present invention and, in particular, as represented in Figure 8A.

[0050] Figures 9A - C represent cross-sectional views of various primary forming tools contemplated for use in the practice of the present invention. In particular: Figure 9A represents a primary forming tool made of a single component; Petition 870250003926, dated 17 / 01 / 2025, page 31 / 160 20 / 55 Figure 9B represents a primary forming tool made of a separate shaft and tip; and Figure 9C represents a primary forming tool made of a separate shaft, tip and bearing.

[0051] Figure 10 represents a partial cross-sectional view of the above embodiments of the present invention with a diagram of a synchronized control system. DETAILED DESCRIPTION

[0052] The present invention relates to a unique double-sided sheet incremental forming apparatus and method, without the use of specifically constructed dies, but rather with tools that can be universally applied to form a variety of shapes with a minimum force ratio.

[0053] By way of illustration only, the present invention is applicable to the shaping of parts and components from sheet materials for all major industries, such as automotive, aerospace, industrial, architectural, engineering, construction and consumer products.

[0054] Figures 1A, 1B and 1C represent a first embodiment (Embodiment 1) of an incremental sheet forming (ISF) system of the invention. This system comprises a sheet feed roller assembly 40 for precisely advancing the workpiece 80, a primary forming tool assembly 10 and a secondary forming tool assembly (e.g., support roller tool assembly 20).

[0055] In Figure 1A, the workpiece 80 is shown formed into its final shape 81. The workpiece 80 comprises a sheet of material (e.g., sheet metal) which may be made of steel, aluminum, plastic, or other formable material. This sheet of material generally begins in a planar state shown in Embodiment 1 as parallel to a reference plane. The reference plane is represented as the XY plane 82 and is defined by the initial configuration of the workpiece 80 before forming. Petition 870250003926, dated 17 / 01 / 2025, page 32 / 160 21 / 55 incrementally to the workpiece. The sheet may also be pre-formed with certain preliminary features before performing further operations according to the present invention.

[0056] The sheet feed roller assembly 40 comprises one or more sets of synchronized rollers 42 (42A - 42H) that are positioned to contact the workpiece 80. Synchronized rollers 42 contact each opposite surface of the workpiece 80, typically along the first and second edges (or marginal edge portions) 88 or 89. However, other engagement surface portions are contemplated.

[0057] The sheet feed roller assembly 40 advances the workpiece 80 forward and backward, preferably along an axis, shown as the Y-axis in Figure 1A. In Embodiment 1, the sheet feed roller assembly 40 comprises four sets of synchronized rollers 42. Two sets of rollers (42A - 42B and 42C - 42D) are positioned along the first edge 88 of the workpiece 80 and two sets (42E - 42F and 42G - 42H) are positioned along the second edge 89 of the workpiece. A first set of these rollers is positioned to contact one surface of the workpiece 80 and a second set of these rollers is positioned to contact the opposite surface of the workpiece 80.

[0058] As shown in Figure 1A, opposing pairs of rollers (e.g., 42A and 42B with 42C and 42D; 42E and 42F with 42G (not shown) and 42H) are preferably positioned directly opposite each other in contact with opposite surfaces of the workpiece 80. These rollers preferably contact and grip opposite surfaces of the workpiece 80 along edges 88 or 89 to drive the workpiece along the Y-axis.

[0059] At least one of the rollers (42A - 42D) on the first edge 88 and at least one of the rollers (42E - 42H) on the second edge 88 interface with motor(s), control systems and software (not shown) to coordinate and synchronize the rotation of the rollers. As Petition 870250003926, dated 17 / 01 / 2025, page 33 / 160 22 / 55 result, the rollers precisely move the workpiece 80 to a desired location, preferably along a translation axis (Y-axis). See also the description of the motor actuation in relation to Figures 6A - D, where in Figure 1A - C, the same motor control system can be used.

[0060] Synchronized rollers 42 preferably comprise a base core which is made of steel, aluminum or other suitable material and may additionally have around its circumference a coating or layer of polyurethane, neoprene, rubber or other suitable material which is sufficiently flexible and resilient to increase the positive grip of the workpiece 80.

[0061] In Figures 1A - C, the primary forming tool assembly 10 is positioned adjacent to a workpiece surface 80 to engage the first (i.e., top) surface of the workpiece and to move in a direction transverse to the workpiece movement, as shown in Embodiment 1 along the X-axis. Thus, this movement of the primary forming tool assembly 10 is perpendicular to the direction in which the workpiece 80 moves (along the Y-axis) as driven by the sheet feed roller assembly 40. The primary forming tool assembly 10 also moves in a direction perpendicular to the XY reference plane 82 of the workpiece 80, which is shown in Embodiment 1 as the Z-axis, so as to be able to enter and exit contact with the first (i.e., top) surface of the workpiece.

[0062] The secondary forming tool assembly comprises a support roll tool assembly 20 preferably having a solid core 21 and having a flexible, compressible or resilient outer material layer 22 (or support roll tool surface portion) that is fixed to the circumference of the core 21 to provide flexible, compressible, resilient and controlled counterforce on the second Petition 870250003926, dated 17 / 01 / 2025, page 34 / 160 23 / 55 surface or lower surface of the workpiece 80, when the primary forming tool assembly 10 engages the opposite (i.e., first or upper) surface of the workpiece.

[0063] In embodiment 1 (see, for example, Figures 1A, B and C), the support roll tool assembly 20 is positioned adjacent to and facing the surface of the workpiece 80, which is opposite to that of the primary forming tool assembly 10. Thus, the workpiece 80 separates the support roll tool assembly 20 from the primary forming tool assembly 10. The support roll tool assembly 20 is elongated, cylindrical and has a longitudinal axis of rotation that extends longitudinally through it, which is positioned along the X-axis, parallel to a direction of movement of the primary forming tool assembly 10, and in contact with the opposite (i.e., lower) surface of the workpiece 80.

[0064] The tip of the primary forming tool assembly 10 and the longitudinal axis of the support roll tool assembly 20 are preferably positioned directly opposite each other on either side of the workpiece 80 along the X-axis. Preferably, the length of the support roll tool assembly 20 is approximately, at least substantially the same as, or greater than, the distance that the primary forming tool assembly 10 can move along the X-axis. As a result, the support roll tool assembly 20 remains formable and in direct contact with the second (i.e., lower) surface of the workpiece 80, as the primary forming tool assembly 10 engages the first (i.e., upper) surface of the workpiece and moves along the X-axis.

[0065] In Figures 1A, 2A and 3A, the roller tool assembly Petition 870250003926, dated 17 / 01 / 2025, page 35 / 160 24 / 55 of support 20 is shown to be positioned away from and not in direct contact with the workpiece 80 for illustrative purposes only. During operation of the apparatus of the invention, the resilient layer 22 of the tool assembly of the support roller 20 is actually positioned facing and in direct engagement with the second (i.e., lower) surface of the workpiece 80. When the primary forming tool assembly 10 engages and applies force on the first surface or on the opposite surface of the workpiece 80, the result is a force localized in the area where the primary forming tool assembly 10 contacts the workpiece 80.

[0066] The primary forming tool assembly 10 and the resilient layer 22 of the support roll tool assembly 20 are actually positioned to provide opposing forces at their points of contact along the X-axis, with the workpiece 80 positioned between them. More specifically, the forming tool assembly 10 and the resilient layer 22 are in indirect contact through the formed workpiece 80 by virtue of the force applied to the first (i.e., top) surface of the workpiece by the primary forming tool assembly 10 and the opposing force applied to the opposite or second (i.e., bottom) surface of the workpiece by the controlled compression of the flexible and resilient layer 22 of the support roll tool assembly 20.The counterforce ratio is controlled by the degree of hardness, thickness, compressibility and resilience resulting from the resilient layer 22 (or the outer surface portion) of the support roller tool assembly 20.

[0067] In addition to rotating along its longitudinal axis, the support roller tool assembly 20 also moves in a direction perpendicular to the XY reference plane 82 of the workpiece 80, shown in Embodiment 1 as the Z-axis. The movement along the Z-axis allows the support roller tool assembly Petition 870250003926, dated 17 / 01 / 2025, page 36 / 160 25 / 55 remains in contact with the workpiece 80, since the primary forming tool assembly 10 exerts precisely controlled opposing forces on the workpiece.

[0068] More specifically, as seen in Figures 1B and C, the tool assembly of the support roller 20 including the resilient layer 22 is positioned along its longitudinal axis on the X-axis to make contact with the lower surface (i.e., second surface) of the workpiece 80, thus creating a continuous narrow zone of contact points along the X-axis. More specifically, this contact zone occurs where the circumference of the resilient layer 22 intersects the lower surface of the workpiece 80. In other words, when the resilient layer 22 and the lower surface of the workpiece 80 are in contact with each other, a narrow area or contact zone is created between them. This zone occurs at the tangent of the circumference of the resilient layer 22 with the lower surface of the workpiece.Simultaneously, the primary forming tool assembly 10 is positioned along the X-axis, facing the upper surface of the workpiece and opposite the contact zone of the resilient layer 22 with the lower surface of the workpiece 80.

[0069] As the primary forming tool assembly 10 pushes down the first surface of the workpiece 80, it exerts force on the workpiece in a given contact area along the X-axis. The workpiece 80, in turn, exerts force on the resilient layer 22 in an area imposed along the narrow contact zone along the X-axis. As a result, the resilient layer 22 is compressed and exerts a counterforce in an opposite area located along the narrow contact zone with the workpiece 80 on the X-axis. With the primary forming tool 10 and the resilient layer 22 exerting force on opposite sides of the workpiece 80, the forces are substantially concentrated. Petition 870250003926, dated 17 / 01 / 2025, p. 37 / 160 26 / 55 in the contact area between the primary forming tool 10 and the workpiece 80. In this contact area or tangency zone, the force exerted by the workpiece 80 on the resilient layer 22 remains advantageously concentrated and localized because of the cylindrical shape of the resilient layer 22, thus preventing warping and tearing of the resulting workpiece. As a result, the apparatus of Embodiment 1 is capable of creating numerous dimensionally complex and asymmetrical configurations on the workpiece 80, as intended by a control system selected at any time during the operation (see, for example, Figure 10).

[0070] Furthermore, the support roller tool assembly 20 has a cylindrical configuration for rotating on its longitudinal axis. When positioned perpendicularly (i.e., X-axis) to the workpiece movement direction (i.e., Y-axis), the support roller tool assembly 20 advantageously allows for precise and rapid positioning of the workpiece 80. The cylindrical configuration of the support roller tool assembly 20 also advantageously allows for a simpler and more compact design of the apparatus itself compared to many previous ISF devices.

[0071] In embodiment 1, the core 21 is a solid rod. The outer resilient layer 22 of the support roller tool assembly 20 is fixed to it and rotates freely together around its longitudinal axis. The resilient layer 22 can be fastened by being rigidly fixed or fixedly attached to the core 21 or, alternatively, fastened by circumferentially surrounding the core, but being able to rotate freely around the core. For example, the resilient layer 22 can be made of various materials or layers so that it can rotate freely by means of a bearing assembly (e.g., plain bearings) positioned around the core 21 as known in the art. In another embodiment, the core 21 can be a hollow tube or cylinder. Petition 870250003926, dated 17 / 01 / 2025, p. 38 / 160 27 / 55 which rotates freely together with the resilient layer 22, around a bearing assembly. In another alternative embodiment, the core 21 may be fixed (i.e., non-rotating), while the resilient layer 22 is able to rotate freely around it. In an alternative embodiment, the rotation of the support roll tool assembly 20 may be controlled by mechanical or electromechanical means known in the art. In a further aspect, the support roll tool assembly 20 includes a compressible and resilient layer 22, and in at least one of the support roll tool assembly and the outer resilient surface portion may rotate around an axis extending through the center of the support roll tool assembly.

[0072] Preferably, the longitudinal axis of the support roller tool assembly 20 is positioned movably, so that the resilient layer 22 can remain in continuous contact with a workpiece surface 80 along the X-axis. Contact with the workpiece 80 also causes the support roller tool assembly 20 to rotate by engagement with the workpiece 80, as the workpiece moves along the Y-axis due to the action of the sheet feed roller assembly 40.

[0073] The rigid core 21 may preferably be constructed of steel, aluminum or other suitable material. The core 21 may be solid or hollow, depending on the size and configuration.

[0074] The resilient layer 22 is preferably manufactured from a resilient and conformable material having compressive strength to allow the material to be shaped under the force applied to the workpiece 80 by the primary forming tool assembly 10. The material selected for the resilient layer 22 is also capable of substantially returning to its original or uncompressed shape when the force of the primary forming tool assembly 10 is applied. Petition 870250003926, dated 17 / 01 / 2025, page 39 / 160 28 / 55 workpiece 80 is removed. For example, the resilient layer 22 can be made of an elastomer, preferably polyurethane. Alternatively, it can also be made of rubber, neoprene, nitrile or other suitable material that is capable of precise, predictable and controlled deformation and resilience when contact is made with the workpiece 80.

[0075] The resilient layer 22 generally has a hardness measured by a durometer ranging from about a Shore 10A to about 80D, preferably from about 30A to about 95A. Depending on the hardness of the selected material, the thickness of the resilient layer 22 can vary between about 0.01 mm and about 25 mm, preferably from about 1.0 mm to about 5.0 mm. When selecting a preferred durometer for the resilient layer 22, a precise and controlled counterforce can be applied to the second surface of the workpiece 80, when the primary forming tool assembly 10 exerts force on the first surface of the workpiece.

[0076] During the forming process, the sheet feed roller assembly 40 is operative for moving the workpiece 80 forward and backward along the Y-axis to its desired location. The primary forming tool assembly 10 is simultaneously capable of movement along the X-axis to a desired location. The support roller tool assembly 20 is simultaneously capable of movement along the Z-axis to a desired location, so as to be in contact with the surface of the workpiece 80. When placed in contact with the workpiece 80, the support roller tool assembly 20 is preferably free to rotate along its longitudinal axis by frictional engagement with the workpiece, as the sheet feed roller assembly 40 moves the workpiece to its desired position along the Y-axis.

[0077] Sheet feed roller assembly 40, primary forming tool assembly 10 and tool assembly. Petition 870250003926, dated 17 / 01 / 2025, page 40 / 160 29 / 55 of the support roller 20 can be controlled by different systems (e.g., mechanical, hydraulic) that can interface directly or indirectly with each other and computing entities to send and receive information about their precise positioning in their desired locations. See also the description of the motor actuation in relation to Figures 6A-D and Figure 9 and the control system in relation to Figure 10, where similar motors, control systems, and software can be used in the arrangement of Figures 1A-C.

[0078] When the workpiece 80, the primary forming tool assembly 10 and the support roll tool assembly 20 move independently to their specified and coordinated positions, the primary forming tool assembly 10 can be brought into support against the workpiece 80 by movement along the Z-axis, which is perpendicular to the original XY reference plane 82 of the workpiece. Simultaneously, the support roll tool assembly 20 can be moved along the Z-axis so as to be in deformable and resilient contact along its longitudinal axis (i.e., along the X-axis) with the workpiece 80.

[0079] When force is applied from the primary forming tool assembly 10 to the workpiece 80, the workpiece begins to conform locally to its desired configuration at the precise point of contact where the force is applied. More specifically, the primary forming tool assembly 10 creates a localized force in the contact area in the X, Y, and Z directions as it traverses along its predetermined path relative to the workpiece 80. As the primary forming tool assembly 10 moves relative to the workpiece 80, the workpiece is continuously formed along a force vector with predetermined magnitudes and components in the X, Y, and Z directions. This force is plastically localized and Petition 870250003926, dated 17 / 01 / 2025, page 41 / 160 30 / 55 permanently forms the workpiece 80 into the desired shape in the area of ​​contact with the workpiece where the force is applied.

[0080] While the primary forming tool assembly 10 exerts force on one surface of the workpiece 80, the support roll tool assembly 20 maintains continuous contact with the opposite surface of the workpiece. As a result of the force being applied by the primary forming tool assembly 10 on the workpiece 80, the resilient layer 22 is deformed to create an opposing reactive force, capable of supporting the workpiece while the workpiece is being formed into its desired shape.

[0081] As the primary forming tool assembly 10 advances along the Z-axis and locally forms the workpiece 80 into the desired configuration, the support roll tool assembly 20 retracts along the Z-axis to the extent necessary to match the feed motion of the primary forming tool assembly 10. Preferably, the resilient layer 22 remains deformed while moving in precise and controlled contact with the workpiece 80 and generates a counterforce that supports the workpiece as the support roll tool assembly moves along the Z-axis. Due to its resilient nature, the resilient layer 22 is selected to be able to substantially return to its original configuration once the primary forming tool assembly 10 retracts along the Z-axis and the sheet feed roll assembly 40 moves the workpiece 80 to a new location along the Y-axis.

[0082] Once workpiece 80 is formed locally to its desired configuration at the selected location, another position for the workpiece is chosen to form the workpiece at a new location. Sheet feed roller assembly 40 then moves workpiece 80 to its selected position along the Y-axis in coordination with the movement. Petition 870250003926, dated 17 / 01 / 2025, page 42 / 160 31 / 55 independent predetermined and pre-programmed movement required of the primary forming tool assembly 10, along the X and Z axes. Furthermore, the independent movement of the workpiece 80 is also coordinated via a control system (not shown) with the specified independent movement of the support roller tool assembly 20 along the Z axis. As a result, the required forming of the workpiece 80 occurs in the selected position.

[0083] Another coordinate is selected and the above sequence continues until the workpiece 80 is fully conformed to the desired configuration. See also Figures 6 to 10 and the accompanying descriptions regarding the implementation of the invention process.

[0084] Figures 2A - C represent a second embodiment (Embodiment 2) of an ISF sheet forming system of the invention. This embodiment comprises a sheet feed belt assembly 43 for precisely advancing the workpiece 80, a primary forming tool assembly 10 and a secondary forming tool assembly (e.g., support roll tool assembly 20).

[0085] In embodiment 2, the sheet feed roller assembly 40 of embodiment 1 is replaced by the sheet feed belt assembly 43 and functions similarly to the sheet feed roller assembly. This assembly comprises pulley assemblies 44A - 44H and continuous, endless belts 46 encircling the rollers. The roller assemblies rotate in contact with continuous belts 46 so that the belts produce high tensile force along the Y-axis at a predetermined speed as the pulleys 44 rotate. Consequently, the belts 46 precisely hold and move the workpiece 80 back and forth, preferably along an axis (shown as the Y-axis in embodiment 2). The belts 46 are configured and dimensioned and are made of a Petition 870250003926, dated 17 / 01 / 2025, p. 43 / 160 32 / 55 material selected to expand the contact area with the workpiece surface 80 over that of pulleys 44A 44H of Mode 1. The additional surface area contacted on the workpiece 80 by the sheet feed belt assembly 43 of Mode 2 increases grip and minimizes possible workpiece slippage to achieve even more precise workpiece positioning.

[0086] Alternative embodiments are contemplated, for example, wherein a plurality of belts is arranged to contact opposite surfaces of the workpiece 80, at least along the edges 88 or 89. Furthermore, it is contemplated that there may be as much as only one belt 46 in contact with a surface of the workpiece 80 with pulleys positioned on the opposite surface of the workpiece.

[0087] Embodiment 2 (see, for example, Figure 2A) illustrates the sheet feed belt assembly 43 as having four sets of pulleys (44A and 44B, 44C and 44D, 44E and 44F, 44G (not shown) and 44H) and four belts 46. One set of rollers (44A and 44B) is located and positioned along the first edge 88 of the workpiece 80 and on a first (i.e., top) surface of the workpiece. A second set of rollers (44C and 44D) is located and positioned on the first edge 88 of the workpiece 80, but on the opposite (i.e., second or bottom) surface of the workpiece. A third set of rollers (44E and 44F) is located and positioned along the second edge 89 of the workpiece 80, which is parallel to the first edge 88 of the workpiece. A fourth set of rollers (44 (not shown) and 44H)) is also located and positioned on the second edge 89 parallel to the first edge 88 of the workpiece 80, but on the opposite surface of the workpiece.

[0088] As shown, continuous belts 46 encircle their pulley assembly 44A - 44H and contact the surface of the part of Petition 870250003926, dated 17 / 01 / 2025, page 44 / 160 33 / 55 workpiece 80 along edges 88 and 89 to hold and move workpiece 80 to a desired location along the Y direction. Belts 46 are preferably configured and sized to be able to provide consistent traction on the surfaces of workpiece 80, for precise movement, allowing predictable and coordinated forward and backward movement of the workpiece along the Y axis.

[0089] At least one of the pulleys 44A or 44B and one of the pulleys 44E or 44F may preferably be driven by synchronized motors (not shown) and control systems that coordinate and drive the rotation of the various surrounding pulleys and belts 46, so as to move and position the workpiece 80 forward and backward, preferably along a translation axis, shown in Embodiment 2 as the Y-axis. In addition, or alternatively, at least one of the pulleys 44C or 44D and one of the pulleys 44G or 44H may also preferably be driven by synchronized motors (not shown) to coordinate and drive the rotation of the various surrounding pulleys and belt, so as to hold and move the workpiece 80 forward and backward, preferably along a translation axis, shown in Embodiment 2 as the Y-axis.

[0090] The pulleys 44 of the sheet 43 feed belt assembly comprise a core made of steel, aluminum or other suitable material known in the art. The belts 46 of the sheet 43 feed belt assembly are composed of urethane, neoprene or other suitable material and are preferably reinforced with fiberglass, aramid, polyamide fiber yarns, such as KEVLAR material, carbon, steel or other suitable material known in the art.

[0091] In addition, belts 46 can be coated with a layer of material, such as urethane, nitrile, rubber or other suitable material known in the art, to increase the coefficient of friction between the belt and the workpiece 80. Petition 870250003926, dated 17 / 01 / 2025, page 45 / 160 34 / 55 The width, thickness, and hardness of the belts 46 are selected to be able to apply precise and consistent traction to the surface of the workpiece 80, for coordinated alignment of the workpiece 80 with the primary forming tool assembly 10 and the secondary forming tool assembly.

[0092] The operation of Mode 2, including the assembly of primary forming tool 10 and the assembly of support roll tool 20, is performed as described in relation to Mode 1, except that the sheet feed roll assembly operation 40 of Mode 1 is replaced by that of sheet feed belt assembly 43, as described.

[0093] The sheet feed belt assembly 43, primary forming tool assembly 10 and support roll tool assembly 20 can be controlled by different systems (e.g., mechanical, hydraulic) that can interface directly or indirectly with each other and computing entities to send and receive information about their precise positioning in their desired locations. See also the description of the motor actuation in relation to Figures 6A - D and Figure 9 and the control system in relation to Figure 10.

[0094] Figures 3A - C represent a third embodiment (Embodiment 3) of the present ISF system. This embodiment comprises the sheet clamping assembly 50 for the workpiece advance 80, the primary forming tool assembly 10 and the support roll tool assembly 20.

[0095] In Embodiment 3, the sheet clamping assembly 50 replaces the sheet feed roller and sheet feed belt assemblies of Embodiments 1 and 2. The sheet clamping assembly 50 comprises a rigid frame 51 and a retainer 52. The workpiece 80 is positioned and clamped between the rigid frame 51 and the retainer 52 capable of restraining with Petition 870250003926, dated 17 / 01 / 2025, page 46 / 160 35 / 55 safety the movement of the workpiece, in relation to the rigid structure 51. The sheet clamping assembly 50 defines an opening that is configured and dimensioned to receive the workpiece 80 between the rigid structure 51 and the retainer 52, yet to allow the workpiece to be clamped and retained by the sheet clamping assembly 50, along at least a portion of the periphery of the workpiece. In other words, the opening in the sheet clamping assembly 50 is defined to provide access to the surfaces of the workpiece 80 to conduct the forming process, using the primary forming tool assembly 10 and the support roll tool assembly 20, while also allowing the workpiece to be clamped within the sheet clamping assembly.

[0096] The retainer 52 may comprise a plurality of clamps (not shown) that are positioned around the perimeter of the workpiece 80. The clamps engage and / or exert sufficient force on the workpiece 80 and on the rigid frame 51 to prevent the workpiece from slipping and to retain its fixed position within the sheet clamping assembly 50. The clamps are preferably provided along several edges or on all edges of the rigid frame 51 to encircle the opening and secure the workpiece 80 therein. Clamps or other mechanism for securely retaining the workpiece 80 within the sheet clamping assembly 50 may be selected and positioned to exert constant, fixed or adjustable force on the workpiece 80 by manual, hydraulic, electric or magnetic actuation according to the art.

[0097] In embodiment 3, the sheet clamping assembly 50 can be advanced by known means to move the workpiece 80 forward and backward along the Y-axis to its desired location in the XY plane. The sheet clamping assembly 50 operates in a manner analogous to that of the sheet feed roller assembly 40 of Embodiment 1. The tool assembly of Petition 870250003926, dated 17 / 01 / 2025, page 47 / 160 36 / 55 primary forming tool assembly 10 and the support roll tool assembly 20 operate as described in relation to embodiments 1 and 2. For example, the primary forming tool assembly 10 is positioned adjacent to a workpiece surface 80, which is secured in its desired position within the sheet clamping assembly 50. The support roll tool assembly 20 is positioned on the opposite surface and maintained in contact with the workpiece 80.

[0098] By way of illustration, the sheet clamping assembly 50 can be moved by one or more motors (not shown) to advance the sheet clamping assembly and the clamped workpiece 80 forward and backward along the Y-axis. As a result, the sheet clamping assembly 50 precisely moves the workpiece 80 forward and backward to a desired location, preferably along a translational axis (Y-axis). The operation of Embodiment 3, including the primary forming tool assembly 10 and the support roll tool assembly 20, is as described in relation to Embodiment 1, except that the operation of the sheet feed roll assembly 40 of Embodiment 1 is replaced by that of the sheet clamping assembly 50, as described.

[0099] The sheet clamping assembly 50, primary forming tool assembly 10 and support roll tool assembly 20 can be controlled by different systems (e.g., mechanical, hydraulic) that can interface directly or indirectly with each other and computing entities to send and receive information about their precise positioning in their desired locations to produce the predetermined forming and the resulting desired shape for the workpiece 80. See also the description of the motor actuation in relation to Figures 6A - D and Figure 9 and the control system in relation to Figure 10.

[00100] Figures 4A and B represent a fourth modality Petition 870250003926, dated 17 / 01 / 2025, page 48 / 160 37 / 55 (Embodiment 4) of an inventive ISF sheet forming machine. This embodiment is a three-layer assembly comprising the sheet clamping assembly 60, secondary forming tool assembly including flat support tool assembly 30 and lower platform 63, which are connected and supported by a plurality of beams 64. Embodiment 4 also includes the primary forming tool assembly 10 and the workpiece 80, which have been previously described in relation to embodiments 1, 2 and 3.

[00101] The sheet clamping assembly 60 comprises a rigid frame 61 and a retainer 62 to restrict movement and be able to clamp the workpiece 80 in a desired position. The sheet clamping assembly 60 and its components, rigid frame 61 and retainer 62, are similar in material, design and configuration to the sheet clamping assembly 50 of Embodiment 3, except that, unlike the sheet clamping assembly 50, the sheet clamping assembly 60 is not directly actuated.

[00102] The flat support tool assembly 30 in Embodiment 4 comprises a rigid flat plate 31 and a flat layer of flexible and resilient surface material 32 attached to the surface of the plate 31, which is the adjacent workpiece 80. The outer layer of material 32 may also be a flat outer surface portion of the flat support tool assembly 30. The plate 31 may be made of steel, aluminum, or some other suitably rigid material known in the art.

[00103] Similar to resilient layer 22 of Modalities 1, 2 and 3, resilient layer 32 of Modality 4 is made of a resilient, deformable and compressible material having a durometer that is selected so that the layer is capable of being deformed under the force applied to the workpiece 80 by the primary forming tool assembly 10 when the workpiece Petition 870250003926, dated 17 / 01 / 2025, page 49 / 160 38 / 55 is formed. The material selected for the resilient layer 32 is also capable of substantially returning to its original configuration as the force of the workpiece 80 (originating from the primary forming tool assembly 10) is removed and the support roll assembly moves away from the second workpiece surface along the Z-axis while the workpiece moves to a newly selected location.

[00104] For example, the resilient layer 32 may be made of an elastomer, preferably polyurethane, as described in relation to Embodiment 1. Alternatively, the resilient layer 32 may also be made of rubber, neoprene, or other suitable durometer material that is capable of flexibility, compression, and deformability when in contact with the workpiece 80, but resilience and elasticity when no longer in contact with the workpiece.In other words, the durometer for the resilient layer 32 will depend on the hardness, compressibility and resilience values ​​of the selected material, which may vary depending on the workpiece material 80 and the desired final shape.

[00105] In embodiment 4, the resilient layer 32 generally has a durometer hardness ranging from about Shore 10A to about 80D, preferably from about 30A to about 95A. Depending on the hardness of the material selected, the thickness of the resilient layer 32 ranges from about 0.01 mm to about 25 mm, preferably from about 1.0 mm to about 5.0 mm.

[00106] The resilient layer 32 preferably comprises a pre-formed sheet of resilient material (as described above) that is fixed by being attached to the rigid plate 31 with an adhesive, a retainer such as clamps or other suitable fastening method known in the art. Alternatively, the resilient layer 32 may be fixed by friction means known in the art.

[00107] Another method for constructing the tool assembly Petition 870250003926, dated 17 / 01 / 2025, page 50 / 160 39 / 55 flat support 30 is to apply a flat layer of an adhesive liquid version of the aforementioned resilient materials to the top surface of the plate 32 and allow the material to cure in place so as to be fixed to the plate. The resilient materials can be made suitably flat by leveling, machining, grinding or other means of fabrication.

[00108] In Embodiment 4 (see, for example, Figures 4A and B), four support beams 64 extend between the sheet clamping assembly 60 and the flat support tool assembly 30 and continue to extend between the flat support tool assembly 30 and the lower platform 63. The support beams 64 can be supplied as solid or hollow tubular elements. The beams 64 are preferably configured and dimensioned so that the flat support tool assembly 30 is able to slide freely along the beams in the Z direction, so as to remain in continuous contact with the workpiece surface 80 during the forming process, while the primary forming tool assembly 10 exerts force on the workpiece.

[00109] In Figure 4A, the support beams 64 are shown as being positioned within the defined openings of the flat support tool assembly 30. However, the beams 64 can be modified or replaced by another suitable means known in the art that would allow vertical movement (i.e., along the Z-axis) of the flat support tool assembly 30, relative to the workpiece 80 (e.g., including rail systems). This sliding movement allows the flat support tool assembly 30 to remain in continuous contact with the workpiece 80, while the primary forming tool assembly 10 exerts force on the workpiece.

[00110] Analogous to the tool assembly operation of the support roller 20 of Modalities 1 - 3, the flat tool assembly Petition 870250003926, dated 17 / 01 / 2025, page 51 / 160 Support bracket 40 / 55 30 is movable along a single axis (Z-axis as shown in Figures 4A and B) and remains nominally flat relative to the sheet clamping mount 60, parallel to the XY plane defined by the workpiece 80.

[00111] By way of illustration, sheet clamping assembly 60 can be moved by one or more motors (not shown) along the Z-axis. Sheet clamping assembly 60, primary forming tool assembly 10 and flat support tool assembly 30 can be controlled by different systems (e.g., mechanical, hydraulic) that can interface directly or indirectly with each other and computing entities to send and receive information about their precise and independent positioning in their desired locations. See also the description of the motor actuation in relation to Figures 6A - D and the description in relation to Figure 9 and the control system in relation to Figure 10.

[00112] In Figures 4A and B, the forming tool 10 can move in the X, Y, and Z directions relative to the sheet clamping assembly 60 and workpiece 80 by different systems (e.g., mechanical or hydraulic) not shown. The rigid structure 61 and the retainer 62 of the sheet clamping assembly 60 can be fixed to the lower platform 63 by means of a series of support beams 64. The flat support tool assembly 30, comprising the plate 31 and the resilient layer 32, is positioned between the sheet clamping assembly 60 and the lower platform 63.

[00113] Figure 5 illustrates an alternative way for operating Mode 4. In Figure 5, Mode 4 has been incorporated into a vertical machining center 70 (hereinafter VMC). In this example, the primary forming tool assembly 10 is inserted into the spindle assembly 72 of VMC 70. The lower platform 63 is fixed to the worktable assembly 71 of VMC 70. Petition 870250003926, dated 17 / 01 / 2025, page 52 / 160 41 / 55

[00114] As discussed in relation to Figures 4A and B, in Figure 5, the rigid structure 61 and the retainer 62 of the sheet clamping assembly 60 can be fixed to the lower platform 63 by means of a series of support beams 64. The flat support tool assembly 30, comprising rigid plate 31 and resilient layer 32, is positioned between the sheet clamping assembly 60 and the lower platform 63. The resulting three-layer apparatus can be moved controllably in three directions (along the X, Y and Z axes) relative to the primary forming tool assembly 10 via VMC 70.

[00115] By moving the worktable assembly 71 together with the spindle assembly 72, VMC 70 provides translational motion along three axes (X, Y, and Z axes) of the workpiece 80 relative to the primary forming tool 10. The vertical movement of the flat support tool assembly 30 along the Z axis can be synchronized, for example, by means of a motion controller of VMC 70, a secondary control, or combinations of the two (not shown) as are known in the art. Furthermore, the flat support tool assembly 30 can also be moved further along the Z axis, towards or away from the workpiece 80, by one or more motors in coordination with VMC 70. See also the description of the motor actuation in relation to Figures 6A-D, the description in relation to Figure 9, and that of the control system in relation to Figure 10.

[00116] Alternative embodiments using other types of machining centers known in the art, such as, for example, horizontal machining centers and 5-axis operational machining centers, are possible and contemplated in this document. Additional embodiments may also include incorporating the primary forming tool assembly 10 and the support flat tool assembly 30 into other existing machinery, according to the art, without departing from it. Petition 870250003926, dated 17 / 01 / 2025, page 53 / 160 42 / 55 of the principles revealed in this document.

[00117] Figures 6A - D, 7 and 8A and B, respectively, show exemplary cross-sectional views of the workpiece 80 undergoing a sequence of incremental forming steps along illustrative work paths, according to embodiments of the present invention.

[00118] Figures 6A - D represent exemplary front cross-sectional views of a workpiece undergoing a sequence of incremental forming steps from its beginning as a flat sheet (see, for example, Figure 6A) through its forming into a final configuration 81 (see, for example, FIG 6D) according to embodiments of the present invention.

[00119] More specifically, Figures 6A - D show the primary forming tool assembly 10, the workpiece 80 and the supporting forming tool assembly 90. The supporting forming tool assembly 90 comprises a resilient surface material layer 92 (or the outer surface portion of the supporting tool assembly 90), fixed to the rigid support 91. The supporting forming tool assembly 90 represents any of the secondary forming tool assemblies of any of the previous embodiments that include any resilient supporting roll tool assembly 20 (see, for example, Figures 1A - C, 2A - C and 3A - C) with resilient layer 22 and core 21 or includes a flat supporting tool assembly 30 (see, for example, Figures 4A - B and 5) with resilient layer 32 and rigid plate 31.

[00120] During the forming process, the workpiece 80 is pressed between the primary forming tool assembly 10 and the supporting forming tool assembly 90. The primary forming tool assembly 10 exerts controlled force on a surface of the workpiece 80. As a result, the workpiece 80 deforms and applies force to Petition 870250003926, dated 17 / 01 / 2025, page 54 / 160 43 / 55 resilient layer 92. In turn, the resilient layer 92 compresses and applies a counterforce to the opposite surface of the workpiece 80, so as to support the workpiece in the localized area or contact the primary forming tool assembly 10. As a result, the workpiece 80 is plastically and permanently formed.

[00121] The resilient layer 92 remains compressed while in contact with the workpiece 80. The resilient layer 92, however, returns to its pre-compressed configuration once the supporting forming tool assembly 90 moves along the Z-axis, away from the workpiece 80, to another pre-programmed and predetermined position.

[00122] During the forming process, the primary forming tool assembly 10 remains firm due to its hardness and rigidity. Due to its plasticity and flexibility, the workpiece 80 is readily and permanently formed by the force applied to it by the primary forming tool assembly 10. In turn, the resilient layer 92 also deforms, temporarily, due to the force exerted on it by the workpiece 80.

[00123] In operation, the resilient layer 92 can be compressed relative to the Z axis, in a range of about 0.0254 mm to 5.08 mm (0.001 to about 0.2 inch) or greater, preferably about 0.127 mm to 2.54 mm (0.005 to 0.1 inch), depending on the material selected, its thickness and the dimensions of the workpiece 80.

[00124] In Figures 6A - D, the primary forming tool assembly 10 and the support forming tool assembly 90 are preferably controlled by an electromechanical positioning system having a predetermined or pre-programmed movement that results in controlled force located on the workpiece 80. In other words, CNC programming techniques are used, which refer to the establishment of the Petition 870250003926, dated 17 / 01 / 2025, page 55 / 160 44 / 55 controlled positioning of the various tools, in order to achieve this result and the desired shaping of the workpiece 80. The means for controlling the progression of the shaping of the workpiece 80, as represented in Figures 6A D, is further described below, in relation to Figures 7, 8A, 8B and 10.

[00125] All modes are preferably driven by such electromechanical means. Servo motors are the preferred electromechanical drive means. Stepper motors can also be used as an electromechanical drive means. In addition, precision hydraulics can be used for one or more of the driven axes of the mechanical system as an alternative. See also Figure 10 and its accompanying description.

[00126] Alternatively, the primary forming tool assembly 10 or the supporting forming tool assembly 90, or both tools, can be pressure-controlled. In this alternative method, one or both the primary forming tool assembly 10 and the supporting forming tool assembly 90 are controlled in the Z direction by an electromechanical positioning system that exerts a directed force on the workpiece 80. This would allow the pressure-controlled tool (or tools) to vary its position on the Z axis in order to maintain a predetermined pressure on its corresponding surfaces of the workpiece 80. In other words, other known CNC programming techniques are used and related to specified pressure values. See US Patent Number 7,536,892, the entire content of which is incorporated herein by reference.

[00127] As seen in Figure 7, the primary forming tool assembly 10 moves illustratively along the external toolpath 83, in a plane offset from the plane defined by the original workpiece 80. The assembly of Petition 870250003926, dated 17 / 01 / 2025, page 56 / 160 45 / 55 Primary forming tool 10 advances along the Z-axis, applying controlled force to the workpiece 80 as shown in Figures 6A-D. As the primary forming tool assembly 10 moves along the outer toolpath 83, the primary forming tool continues to apply force to the workpiece 80. While the workpiece 80 is being formed, the resilient layer 92 of the secondary forming tool assembly (e.g., support forming tool assembly 90) also deforms and applies a controlled counterforce to the workpiece from the opposite surface. As a result, the workpiece 80 receives a localized force in the area where it is contacted by the forming tool assembly 10 and is plastically formed along a selected toolpath.

[00128] By way of further illustration, Figure 7 depicts the workpiece 80 which has a work area with multiple toolpaths, where the forming of the workpiece increases towards the center of the workpiece. As a result, once the operation of the first toolpath 83 is completed, the supporting forming tool assembly 90 moves away (along the Z-axis) by a predetermined distance from the bottom surface of the workpiece 80 and the primary forming tool assembly 10 moves towards the workpiece 80, along the second toolpath 84 along the Z-axis to provide sufficient reactive force to the workpiece to counteract the forming force on the workpiece, from the primary forming tool assembly 10.The supporting forming tool assembly 90 moves continuously in conjunction with the movement of the primary forming tool assembly 10, to remain substantially opposite the tip of the primary forming tool assembly, with the workpiece in between. As a result, the forming forces are localized. Petition 870250003926, dated 17 / 01 / 2025, page 57 / 160 46 / 55 held in the workpiece.

[00129] The primary forming tool assembly 10 forms the surface of the workpiece 80 by forcing the workpiece into the resilient layer 92 (see Figures 6A and 7). When completed, the forming process begins again on the next toolpath 84 (see Figure 7). The process is repeated (see Figures 6B and 7) based on each successive toolpath until the forming process is completed and the workpiece 80 is formed into its final configuration 81 (see Figures 6C, 6D and 7).

[00130] As illustrated in Figures 8A and B, other toolpath methods can be used to create configurations with more than one formed or work area 100 per sheet of material. Specifically, Figures 8A and B show the workpiece 80 with two work areas 100 that are separated from each other. These figures represent a method for forming multiple forms in the two separate work areas on the workpiece 80, which is undergoing a sequence of incremental forming steps, according to embodiments of the present invention. The method is applicable to workpieces with one or more work areas.

[00131] Figure 8A represents toolpaths 101 to 108. Toolpaths 101, 103, 105 and 107 are applicable to a first formed area 100 and toolpaths 102, 104, 106 and 108 are applicable to a second formed area 100.

[00132] Figure 8B represents an exemplary final front cross-sectional view of a workpiece that has undergone a sequence of multiple incremental forming steps according to the embodiments of the present invention, in its newly formed final configuration 81. More specifically, Figure 8B shows the primary forming tool assembly 10 and the forming tool assembly. Petition 870250003926, dated 17 / 01 / 2025, pp. 58 / 160 47 / 55 secondary (e.g., supporting forming tool assembly 90). The secondary forming tool assembly comprises resilient layer 92 (comparable to resilient layer 22 of embodiments 1-3 and resilient layer 32 of embodiment 4) and rigid support 91 (comparable to core 21 of embodiments 1-3 and rigid plate 31 of embodiment 4).

[00133] In this example, the primary forming tool assembly 10 follows toolpaths 101 - 108 in numerical sequence (i.e., order of 101, 102, 103, 104, 105, 106, 107 and finally 108). In this example, toolpaths 101 and 102, 103 and 104, 105 and 106, 107 and 108, respectively, are positioned along an XY plane substantially in the same position on the Z axis.

[00134] According to this illustrative incremental forming method, the primary forming tool assembly 10 moves to the selected Z-axis position of the toolpath 101, somewhere along the length of the toolpath 101. The resilient support forming tool assembly 90 moves in the Z-axis direction substantially to the same Z-axis position as that of the toolpath 101 (or a pre-selected dimensional offset in the positive or negative Z-axis direction) which is substantially the same as that of the toolpath 101. The primary forming tool assembly 10 then proceeds to exert force along the toolpath 101 as the workpiece 80 forms and the resilient support forming tool assembly 90 supports the workpiece.When the movement along the toolpath 101 is completed, the primary forming tool assembly 10 then retracts in the Z-axis direction, away from the workpiece 80, beyond the original XY reference plane 82 of the workpiece 80, to the XY clearance plane 109 (see Figure 8B). Petition 870250003926, dated 17 / 01 / 2025, page 59 / 160 48 / 55

[00135] The clearance plane 109 is located at a sufficient distance from the reference plane 82 to allow the primary forming tool assembly 10 not to contact the workpiece surface 80. Next, the primary forming tool assembly 10 proceeds to a newly selected XY location above the toolpath 102, while still positioned along the clearance plane 109. The primary forming tool assembly 10 then moves toward the workpiece 80 substantially to the same Z-axis position on the toolpath 102 as previously selected for the toolpath 101.

[00136] The primary forming tool assembly 10 proceeds to exert force along the toolpath 102 as the workpiece 80 forms and the resilient support forming tool assembly 90 supports the workpiece. As a result, the forming ratio of the workpiece 80 along the toolpath 102 is substantially the same forming ratio along the toolpath 101. During the movement of the primary tool assembly 10 along the toolpath 101 and the toolpath 102, in this example, the support forming tool assembly 90 did not change its position on the Z-axis.

[00137] The primary forming tool assembly 10 retracts again in the Z-axis direction, away from the workpiece 80, past the original reference plane 82 and back to the clearance plane 109. The primary forming tool assembly 10 then proceeds to an XY location above the toolpath 103. The resilient support forming tool assembly 90 also moves away from the workpiece 80 to a pre-selected Z-axis position (or a dimensional offset in the positive or negative dimension in the Z-axis direction). The forming tool assembly Petition 870250003926, dated 17 / 01 / 2025, pp. 60 / 160 49 / 55 primary 10 then moves to the selected Z-axis level of toolpath 103 and proceeds along toolpath 103. When forming is completed along toolpath 103, the primary forming tool assembly 10 proceeds to a newly selected XY location above toolpath 104, while still positioned along clearance plane 109. The primary forming tool assembly 10 then moves toward workpiece 80 substantially to the same Z-axis position on toolpath 104 as previously selected for toolpath 101.

[00138] The primary forming tool assembly 10 proceeds to exert force along the toolpath 104 as the workpiece 80 forms and the resilient support forming tool assembly 90 supports the workpiece. As a result, the forming ratio of the workpiece 80 along the toolpath 104 is substantially the same forming ratio as along the toolpath 103. During the movement of the primary tool assembly 10 along the toolpaths 103 and 104 in this example, the resilient support forming tool assembly 90 did not substantially change its position on the Z-axis.

[00139] This method is then repeated and continued for toolpaths 105 and 106, 107 and 108, until the workpiece 80 is formed into its final shape with multiple forming. In other words, those toolpaths that must be formed substantially at the same Z-axis level are processed all in sequence, so as to form all toolpaths having substantially the same Z-axis level as the final configuration.

[00140] According to the method of the invention, multiple conformations in a single sheet of material do not need to have the Petition 870250003926, dated 17 / 01 / 2025, page 61 / 160 50 / 55 same final shape or the same final forming ratio. When different multiple forming configurations are required on a single sheet of material, the incremental process above would begin along the toolpaths where the lowest forming ratio is contemplated for the multiple forming. Then, the process moves to the toolpaths where the next forming ratio is contemplated and continues until all toolpath configurations are completed and the final shape is achieved.

[00141] Figures 9A - C represent cross-sectional views of various primary forming tool assemblies according to the present invention.

[00142] Figure 9A represents the primary forming tool assembly 10 as comprising a solid tool made of any suitable rigid material, generally hardened steel or engineered ceramic. The tip of the primary forming tool assembly that would contact the workpiece 80 may be of any shape. Depending on the application, the tip preferably has a spherical shape. The primary forming tool assembly 10 may also have a surface treatment, such as additional hardening or coatings, as is known in the art for metalworking tools.

[00143] Figure 9B represents the primary forming tool assembly 10 as comprising the tool shaft 12 and the fixed tool tip 11. The tool shaft 12 may be made of any suitable material, generally hardened steel. The tool shaft 12 may also have additional surface treatment, such as hardening or coatings, as is known in the machining tool art.

[00144] The tip of tool 11 preferably has a spherical shape, although other shapes are possible and Petition 870250003926, dated 17 / 01 / 2025, page 62 / 160 51 / 55 contemplated. The tip of tool 11 can be made of any suitably hard and rigid material, preferably ceramic or alloy steel. The tip of tool 11 can be fixedly fitted to the shaft of tool 12, either mechanically or by adhesion. Alternatively, the tip of tool 11 can be designed to be retained and rotate freely against the shaft of tool 12, as mentioned below.

[00145] Figure 9C represents the primary forming tool assembly 10 as comprising the tool shaft 12, the tool tip 11 and the plain bearing 13 positioned between the tool tip 11 and the tool shaft 12. This embodiment acts analogously to that of a ballpoint pen with its rotating tip.

[00146] All or part (e.g., tip 11) of the primary forming tool assembly 10 preferably comprises engineered grade ceramic material. In other words, one or more components 11, 12 and 13 in each of Figures 9A - C may preferably be made of engineered ceramic with a hardness greater than the hardness of the workpiece 80. Depending on the actual material of the workpiece 80, various technical grade or engineered ceramics may be used, including oxide ceramics and non-oxide ceramics, such as, but not limited to, silicon nitride, aluminum nitride, zirconium oxide, silicon carbide and aluminum oxide. Silicon nitride (Si3N4) ceramic is generally preferred. The hardness of the primary forming tool assembly 10 and its tool tip 11 is greater than that of the workpiece 80.

[00147] Depending on the size of the workpiece being formed and the level of detail required for the final forming, the tip of tool 11 preferably has a spherical shape and its diameter preferably ranges from about 3.175 mm to 50.8 mm (0.125 inches to about 2.0 inches), more Petition 870250003926, dated 17 / 01 / 2025, page 63 / 160 52 / 55 preferably about 12.7 mm to 38.10 mm (0.50 inches to about 1.50 inches) for larger workpieces and preferably about 3.175 mm to 12.7 mm (0.125 inches to about 0.5 inches) for smaller workpieces.

[00148] It has also been verified that incorporating a engineered grade ceramic as part of the primary forming tool assembly 10 minimizes the need for constant lubrication of the workpiece, which would otherwise be required by prior art devices. Advantageously, engineered ceramic spheres (e.g., particularly silicon nitride), when used as the tip of the tool 11 according to the method of the invention, do not break despite the resulting force and friction applied to the workpiece 80. These engineered ceramic tips also create a polished or buffed finish for the formed material sheet, such as sheet metal.

[00149] Suitable materials for plain bearing 13 include, but are not limited to, ceramic, metal or plastic according to known bearing materials.

[00150] Figure 10 represents a partial cross-sectional view of embodiments of the present invention, in combination with a synchronized control system. Figure 10 shows the synchronized controller assembly 85, non-contact measuring sensor 86, and contact measuring sensor 87. Figure 10 also shows the primary forming tool assembly 10 and the secondary forming tool assembly (e.g., support forming tool assembly 90). The secondary forming tool assembly comprises a resilient layer 92 (comparable to the resilient layer 22 of embodiments 1-3 and the resilient layer 32 of embodiment 4) and a rigid support 91 (comparable to the core 21 of embodiments 1-3 (see, for example, Figures 1A-B, 2A-B, and 3A-B) and the rigid plate 31 of embodiment 4 (see, for example, Figures 4A-B and 5)). Petition 870250003926, dated 17 / 01 / 2025, page 64 / 160 53 / 55

[00151] In Figure 10, one or more controllers or control modules can be provided for synchronized control operation applicable with the components described in the embodiments above. By way of illustration, the synchronized controller assembly 85 monitors and controls the precise positioning of the sheet feed roller assembly 40 (see, for example, Figures 1A - C) or sheet feed belt assembly 43 (see, for example, Figures 2A - C) or sheet clamping assembly 50 (see, for example, Figures 3A - C) or work table assembly 71 (see, for example, Figure 5) of the previous embodiments (not all components are shown in Figure 10), primary forming tool assembly 10 and secondary forming tool assembly 90 (similar to the support roller tool assembly 20 (see, for example, Figures 1A - B, 2A - B and 3A - B) or support flat tool assembly 30 (see, for example, Figures 4A - B and 5)).The synchronized controller assembly 85 can interact with the various subsystems directly. Alternatively, the synchronized controller assembly 85 can interact indirectly, obtaining position information for each subsystem, in order to determine and provide coordinated control.

[00152] In Figure 10, the synchronized controller assembly 85 can operate based on NC (numerical control) data according to the technique. The synchronized controller assembly 85 can be adapted to receive CAD data from which numerical control data is derived to form the workpiece 80 to design specifications. The control assembly 85 can monitor the position and forming process of the workpiece 80 via a contact sensor 87 that physically contacts the workpiece 80, or without physical contact via a non-contact sensor 86 (i.e., laser or optical measuring system). The control system including the synchronized controller assembly 85, Petition 870250003926, dated 17 / 01 / 2025, pages 65 / 160 54 / 55 contact sensor 87 and non-contact sensor 86 can monitor the position of the workpiece 80 at the beginning of the forming process of the invention and preferably repeatedly throughout the forming process.

[00153] According to Figure 10, a non-contact sensor 86 or contact sensor 87 is provided as described above, to measure the forming ratio of the workpiece 80 at specified positions along the workpiece forming path. The resulting measurements from sensors 86 or 87 are compared to a predetermined forming ratio at the same specified positions along the forming path. The resulting compared measurements are relayed to the control assembly 85. The control assembly 85 then adjusts the position of at least one of the primary forming tool assembly 10 and supporting forming tool assembly 90, relative to the pre-programmed forming ratios required along the path, so as to form the workpiece into the predetermined shape. See also US Patent Number 7,536,892.

[00154] Although the control system represented in Figure 10 is shown in connection with a preferred embodiment, this control system can be used with any of the embodiments of the invention that are described in this document.

[00155] Detailed embodiments of the present invention are disclosed herein. However, it should be understood that the embodiments disclosed are merely exemplary of the invention, which may be carried out in various alternative forms. The figures are not necessarily to scale. Some features may be exaggerated or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but only as a representative basis for the claims and / or as a basis. Petition 870250003926, dated 17 / 01 / 2025, page 66 / 160 Figure 55 / 55 is representative for teaching someone skilled in the art how to employ the present invention in various ways.

[00156] Furthermore, in the figures, reference is made to the X, Y, and Z axes of a three-dimensional orthogonal coordinate system in relation to the movement of the various components (e.g., sheet feed roller assembly 40 or sheet feed belt assembly 43 or sheet clamp assembly 50 or sheet clamp assembly 60; primary forming tool assembly 10; and support roller tool assembly 20 or support flat tool assembly 30 or support forming tool assembly 90), all in relation to each other. It should be understood that the movement of the various components is intended to be represented in relation to the movement of each of the other components and a reference plane, as applicable (i.e., defined by the initial workpiece setup before incremental forming).

[00157] In addition, reference is made to certain surfaces being first or second surfaces, top or bottom, or vertical or horizontal and the like. These directional descriptions should be considered in relation to the appropriate X, Y and Z axes, as shown in the applicable figures.

[00158] Furthermore, the reference plane is represented as the XY plane 82 in Figures 1A, 6A-D and 8B. For simplicity, the reference plane is not shown in the other drawings, but is intended to be the generally initial planar configuration of the workpiece 80, along an XY plane prior to incremental forming. Petition 870250003926, dated 17 / 01 / 2025, page 67 / 160

Claims

1 / 12 CLAIMS 1. Apparatus for incrementally forming a workpiece (80) made of sheet metal or plastic material, the workpiece (80) having first and second opposite surfaces positioned in an XY plane (82) of a three-dimensional orthogonal coordinate system X, Y, Z, characterized in that it comprises: a. a primary forming tool assembly (10) positioned adjacent to and facing the first surface of the workpiece (80), the primary forming tool assembly (10) comprising a tool shaft (12) with a tip (11) facing the first surface of the workpiece (80); b. a secondary forming tool assembly (20, 30, 90) having a compressible and resilient outer surface layer of material (22, 32, 92) and positioned adjacent to and facing the second surface of the workpiece (80); and c. a sheet fastening assembly (40, 43, 50,60) to fix the workpiece (80) between the primary forming tool assembly (10) and the secondary forming tool assembly (20, 30, 90), wherein: at least two of the sheet clamping assembly (40, 43, 50, 60), the primary forming tool assembly (10) and the secondary forming tool assembly (20, 30, 90) are configured and arranged to move independently, in a predetermined sequence and pattern relative to each other, the tip (11) of the tool shaft (12) of the primary forming tool assembly (10) is configured and arranged to be positioned at a predetermined Z coordinate along the Z axis, exerting a forming force in a contact area on the first surface of the workpiece (80) while the secondary forming tool assembly (20, 30, 90) is positioned opposite the Petition 870260055096, dated 08 / 06 / 2026,page. 10 / 34 2 / 12 position of the tip (11) of the tool shaft (12) of the primary forming tool assembly (10) to exert a counterforce against the second surface of the workpiece (80), therefore, to support the workpiece (80), and the tip (11) of the tool shaft (12) is further configured and arranged to be adjustablely positioned at each of a predetermined set of XY coordinates relative to the workpiece (80) parallel to the XY plane (82), while the tip (11) of the tool shaft (12) remains in contact relation with the first surface of the workpiece (80) at the same predetermined Z coordinate position, so as to follow a predetermined forming path relative to the workpiece (80) parallel to the XY plane (82), wherein at least two of the components, the sheet clamping assembly (40, 43, 50, 60), the primary forming tool assembly (10) and the tool assembly secondary conformation (20, 30,90) are configured and arranged so that the tip (11) of the tool shaft (12) of the primary forming tool assembly (10) progresses incrementally to another predetermined Z coordinate, after forming the predetermined forming path, while the secondary forming tool assembly (20, 30, 90) progresses and positions itself in the opposite direction to the position of the tip (11) of the tool shaft (12) of the primary forming tool assembly (10), in order to exert a counterforce against the second surface of the workpiece (80), in proximity to the tip (11) of the tool shaft (12) of the primary forming tool assembly (10), thus providing support to the workpiece (80).

2. Apparatus, according to claim 1, characterized in that at least two of the sheet clamping assembly (40, 43, 50, 60), of the primary forming tool assembly (10) and of the secondary forming tool assembly (20, 30, 90) are configured and arranged so that the tip (11) of the tool shaft (12) of the primary forming tool assembly (10) moves away from the sheet clamping assembly (40, 43, 50, 60) in the Z direction before progressing incrementally to the other predetermined Z coordinate.

3. Apparatus, according to claim 1, characterized in that the tip (11) of the tool shaft (12) comprises a ball roller that is rotatably fixed to the tool shaft (12).

4. Apparatus, according to claim 2, characterized in that the tip (11) of the tool shaft (12) is integrally formed with the tool shaft (12).

5. Apparatus, according to claim 1, characterized in that it further comprises a control system (85, 86, 87) simultaneously coordinating the respective movements of at least two of the sheet clamping assemblies (40, 43, 50, 60), the primary forming tool assembly (10) and the secondary forming tool assembly (20, 30, 90).

6. Apparatus, according to claim 5, characterized in that the control system (85, 86, 87) is configured to move one or both of the primary forming tool assembly (10) and the sheet clamping assembly (40, 43, 50, 60) in order to cause the tip (11) of the primary forming tool shaft (12) to follow the predetermined forming path in relation to the workpiece (80).

7. Apparatus according to claim 6, characterized in that the control system (85, 86, 87) includes at least one sensor (86, 87) for measuring the amount of forming of the workpiece (80) at one or more specified positions along the forming path relative to the workpiece (80).

8. Apparatus, according to claim 7, characterized in that at least one sensor (86, 87) includes at least one non-contact type sensor (86) for measuring the amount of workpiece (80) forming without physical contact with the workpiece (80).

9. Apparatus according to claim 7, characterized in that at least one sensor (86, 87) includes at least one contact-type sensor (87) for measuring the amount of workpiece (80) forming by means of physical contact with the workpiece (80).

10. Apparatus, according to claim 1, characterized in that the sheet clamping assembly (40, 43, 50, 60) comprises a sheet feed assembly (40) having at least one set of rollers (42) in contact with the first and second surfaces of the workpiece (80), the set of rollers (42) being configured and arranged to move the workpiece (80) in a direction parallel to the XY plane (82).

11. Apparatus, according to claim 1, characterized in that the sheet clamping assembly (40, 43, 50, 60) comprises a sheet feed assembly (43) having at least one continuous belt (46) encircling and contacting a set of rotating pulleys (44), the belt (46) being arranged to be positioned in contact relation with the first or second surfaces of the workpiece (80) and being capable of moving the workpiece (80) in a direction parallel to the XY plane (82).

12. Apparatus, according to claim 1, characterized in that the sheet clamping assembly (40, 43, 50, 60) comprises a sheet clamping assembly (50, 60) that provides an opening for access to the workpiece (80) by mounting a primary forming tool (10) on the first surface of the workpiece (80) and by mounting a secondary forming tool (20, 30, 90) on the second surface of the workpiece (80).

13. Apparatus, according to claim 12, characterized in that the sheet fastening assembly (50, 60) Petition 870260055096, dated 08 / 06 / 2026, page 13 / 34 5 / 12 comprises a rigid structure (51, 61) and a retainer (52, 62).

14. Apparatus, according to claim 12, characterized in that the sheet clamping assembly (50, 60) comprises a plurality of clamps configured and arranged to be fastened to the workpiece (80) around a perimeter of the workpiece (80).

15. Apparatus, according to claim 1, characterized in that the secondary forming tool assembly (20, 30, 90) comprises: a flat surface portion (31, 91) that is positioned parallel to the XY plane (82), wherein: the compressible and resilient outer surface layer of the material (22, 32, 92) of the secondary forming tool assembly (30, 90) is fixed to the flat surface portion (31, 91) and positioned to face the second workpiece surface (80).

16. Apparatus, according to claim 1, characterized in that the secondary forming tool assembly (20, 30, 90) comprises: a support roll tool assembly (20) having an inner core (21) for rotating about a longitudinal axis of the support roll tool assembly (20), wherein: the compressible and resilient outer surface layer of the material (22) is fixed to the inner core (21) and positioned to face the second workpiece surface (80), a longitudinal axis of the support roll tool assembly (20) being positioned parallel to the XY plane (82).

17. Apparatus, according to claim 16, characterized in that the inner core (21) of the support roller tool assembly (20) has a cylindrical core.

18. Method for incrementally forming a workpiece (80) made of sheet metal or plastic material, the workpiece (80) having at least one work area and Petition 870260055096, dated 08 / 06 / 2026, page 14 / 34 6 / 12 having first and second opposite and parallel surfaces positioned in an XY plane (82) of a three-dimensional orthogonal coordinate system X, Y, Z, characterized in that it comprises the steps of: a. providing an apparatus having: i. a primary forming tool assembly (10) facing the first surface of the workpiece (80), the primary forming tool assembly (10) comprising a tool shaft (12) having a tip (11) facing the first surface of the workpiece (80); ii. a secondary forming tool assembly (20, 30, 90) having a compressible and resilient outer surface layer of the material (22, 32,92) which is facing the second surface of the workpiece (80); and iii. a sheet clamping assembly (40, 43, 50, 60) for securing the workpiece (80) between the primary forming tool assembly (10) and the secondary forming tool assembly (20, 30, 90), wherein at least two of the primary forming tool assembly (10), the secondary forming tool assembly (20, 30, 90) and the sheet clamping assembly (40, 43, 50, 60) are configured and arranged to move independently in a predetermined sequence and pattern relative to each other; b. Position at least one of the secondary forming tool assembly (20, 30, 90) and the sheet clamping assembly (40, 43, 50, 60) so that the compressible and resilient outer surface layer of the material is in contact with the second surface of the workpiece (80).within the work area and opposite a position of the primary forming tool assembly (10) relative to the XY plane (82); Petition 870260055096, dated 08 / 06 / 2026, page 15 / 34 7 / 12 c. advance at least one of the primary forming tool assembly (10), the secondary forming tool assembly (20, 30, 90) and the sheet clamping assembly (40, 43, 50, 60) along the Z axis to cause the tip (11) of the tool shaft (12) to be positioned at a predetermined Z coordinate to contact and exert a forming force on the first surface of the workpiece (80) and cause the compressible and resilient outer surface layer of the material (22, 32, 92) of the secondary forming tool assembly (20, 30, 90) to be positioned opposite the position of the tip (11) of the tool shaft (12) of the primary forming tool assembly (10),and thus: compress the compressible and resilient outer surface layer of the material (22, 32, 92) of the secondary forming tool assembly (20, 30, 90) to support the second surface of the workpiece (80) while the workpiece (80) is being formed; d. move one or both of the primary forming tool assembly (10) and the sheet clamping assembly (40, 43, 50, 60) to position the primary forming tool assembly (10) relative to the workpiece (80) parallel to the XY plane (82) along a predetermined set of XY coordinates, while the tip (11) of the tool shaft (12) remains in contact relation with the first surface of the workpiece (80) at the same predetermined Z coordinate position, so as to follow a predetermined forming path relative to the workpieces (80) parallel to the XY plane (82),and repeat steps “ba “d to advance at least one of the primary forming tool assembly (10), secondary forming tool assembly (20, 30, 90) and sheet clamping assembly (40, 43, 50, 60) along the Z axis to make the tip (11) of the tool shaft (12) be Petition 870260055096, dated 08 / 06 / 2026, page. 16 / 34 8 / 12 positioned at another predetermined Z coordinate to contact and exert a forming force on the first surface of the workpiece (80) and to cause the compressible and resilient outer surface layer of the material (22, 32, 92) of the secondary forming tool assembly (20, 30, 90) to be positioned opposite the position of the tip (11) of the tool shaft (12) of the primary forming tool assembly (10), thus compressing the compressible and resilient outer surface layer of the material (22, 32, 92) of the secondary forming tool assembly (20, 30,90) to support the second surface of the workpiece (80) while the workpiece (80) is being formed.

19. Method, according to claim 18, characterized in that it further comprises: repeating the steps “ba” and using sequentially progressive incremental values ​​for the predetermined Z coordinate position to form one or more additional formation paths.

20. Method according to claim 19, characterized in that it further comprises the steps of: f. providing a control assembly that is configured and arranged to simultaneously coordinate the respective positioning of two or more of the primary forming tool assembly (10), the secondary forming tool assembly (20, 30, 90) and the sheet clamping assembly (40, 43, 50, 60) relative to each other; g. providing at least one sensor to measure the forming ratio of the workpiece (80) at specified positions along the forming paths of the workpiece (80); h. comparing sensor measurements to a predetermined forming value at one or more positions along the forming paths; i. relaying the resulting compared measurements to the control assembly; ej.adjust the position of at least one of the primary forming tool assembly (10), the secondary forming tool assembly (20, 30, 90) and the sheet clamping assembly (40, 43, 50, 60) in relation to the progressive incremental values ​​for the predetermined Z coordinate position along the forming paths in order to form the workpiece (80).

21. Method according to claim 20, characterized in that it further comprises the step of selecting at least one supplied sensor, so as to be of the non-contact type, such that the sensor measures the conformation ratio of the workpiece (80) without physically contacting the workpiece (80).

22. Method according to claim 20, characterized in that it further comprises the step of selecting at least one supplied sensor, so as to be of the contact type, such that the sensor measures the proportion of workpiece (80) forming in physical contact with the workpiece (80).

23. Method according to claim 18, characterized in that the workpiece (80) has at least first and second work areas that are separated from each other, further comprising the following steps: f. repositioning one or more of the primary forming tool assembly (10) and the sheet clamping assembly (40, 43, 50, 60), in a predetermined set of XY coordinates within the second or subsequent work area, whereby the tip (11) of the tool shaft (12) of the primary forming tool assembly (10) is positioned adjacent to the first surface of the workpiece (80); g. position at least one of the secondary forming tool assembly (20, 30, 90) and the sheet clamping assembly (40, 43, 50, 60) so that the compressible and resilient outer surface layer of the material (22, 32, 92) is in Petition 870260055096, dated 08 / 06 / 2026, page.18 / 34 10 / 12 contact with the second surface of the workpiece (80) within the second or subsequent work area and opposite to a position of the primary forming tool assembly (10) relative to the XY plane (82); h. advance one or both of the primary forming tool assembly (10) and the sheet clamping assembly (40, 43, 50, 60) towards the workpiece (80) in the Z direction within the second or subsequent work area, so that the tip (11) of the tool shaft (12) of the primary forming tool assembly (10) is positioned at the other predetermined Z coordinate that was selected for the first or previous work area in the step and so as to contact and exert the forming force on the first surface of the workpiece (80) in a contact area within the second or subsequent work area, thus: i. forming the workpiece (80) into a predetermined configuration; and ii.compress the compressible and resilient outer surface layer of the material (22, 32, 92) of the secondary forming tool assembly (20, 30, 90) to support the second surface of the workpiece (80), resulting in a localized force on the workpiece (80), within the contact area while the workpiece (80) is being formed; and i. move one or both of the primary forming tool assembly (10) and the sheet clamping assembly (40, 43, 50, 60) to position the primary forming tool assembly (10) in relation to the second or subsequent workpiece area (80) parallel to the XY plane (82) along another predetermined set of XY coordinates, while the tip (11) of the tool shaft (12) remains in contact relation with the first workpiece surface (80) at the same predetermined Z coordinate, so as to follow a Petition 870260055096, dated 08 / 06 / 2026, page.19 / 34 11 / 12 predetermined path of formation in relation to the second or subsequent work area of ​​the workpiece (80) parallel to the XY plane (82), as the workpiece (80) is consistently formed in the Z direction in the second or subsequent work area.

24. Method according to claim 23, characterized in that it further comprises the step of: i. repeating the sequence of steps “ba” of “fa”h one or more times, wherein the value of the predetermined Z coordinate used in each of the one or more repeated sequences of steps “ba” of “fa”h is incrementally advanced by a previous value of the predetermined Z coordinate.

25. Method according to claim 24, characterized in that the repeated sequences of steps “ba” and “fa” are continued to form additional formation paths in each of the first and second or subsequent work areas.

26. Method according to claim 19, characterized in that at least one of the primary forming tool assembly (10), of the secondary forming tool assembly (20, 30, 90) and of the sheet clamping assembly (40, 43, 50, 60) is advanced to cause the tip (11) of the tool shaft (12) to be repositioned along the Z axis in a direction towards the secondary forming tool assembly (20, 30, 90) as each predetermined Z coordinate position is progressively advanced.

27. Method according to claim 19, characterized in that step “e” further comprises the substep of: retracting at least one of the primary forming tool assembly (10) or sheet clamping assembly (40, 43, 50, 60) so that the primary forming tool assembly (10) is positioned away from the first workpiece surface (80) along the Z axis before advancing towards the first workpiece surface (80) along the Z axis in the repeated step c.

28. Method according to claim 27, characterized in that step e further comprises the substep of: retracting at least one of the secondary forming tool assembly (20, 30, 90) or sheet clamping assembly (40, 43, 50, 60), such that the secondary forming tool assembly (20, 30, 90) is positioned away from the second workpiece surface (80) before the compressible and resilient outer surface layer of the material (22, 32, 92) comes into contact with the second workpiece surface (80) in repeated step b.

29. Method according to claim 23, characterized in that step g includes the substeps of: retracting at least one of the primary forming tool assembly (10) or sheet clamp assembly (40, 43, 50, 60) so that the primary forming tool assembly (10) moves away from the first workpiece surface (80) along the Z axis, and repositioning at least one of the primary forming tool assembly (10) and / or sheet clamp assembly (40, 43, 50, 60) at a predetermined set of XY coordinates within the second or subsequent work area adjacent to the first workpiece surface (80), so that the tip (11) of the tool shaft (12) is in contact relation with the first workpiece surface (80) at the same predetermined Z coordinate that was selected for the first or previous work area. Petition 870260055096, dated 08 / 06 / 2026, page 21 / 34

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