Hello Jim, can you initially share your background in metal pressings and how you arrived at your current role? 

I’m 56 years old and have been in the metal pressing industry since I was 16. I completed a four-year apprenticeship as a toolmaker, which set the foundation for my career. After that, I transitioned to press tool design and part feasibility. My journey at Jaguar Land Rover (JLR) involved managing extensive tooling programs and overseeing the Press Shop at Castle Bromwich as a Tooling, Engineering, and Launch Manager for a decade. In 2013, I shifted gears to focus on supplier issues and part feasibility, ultimately leading to the establishment of a team dedicated to managing feasibility starting in 2020. I led that team for five years before retiring from JLR. With 40 years of experience, I’ve gained deep insights into everything from progressive tooling to tandem line tooling for large skins. 

Why is cutting waste so critical for manufacturers worldwide? 

Waste material is a significant concern in metal pressing. Historically, a global target of 55% utilization was established to optimize metal efficiency when producing pressed parts. However, with today’s emphasis on sustainability and reducing CO2 emissions, it’s imperative to minimize waste throughout the production process. Implementing strategies such as better blank utilization and transitioning to controlled forming for blank developments—rather than relying solely on traditional draw dies—can significantly reduce scrap costs and improve manufacturing efficiency. Additionally, localizing tool manufacturing can lessen the CO2 footprint by diminishing the transportation of tools across the globe. 

How have methods of analysis in metal pressing evolved over the years? 

In my early years in metal forming, we used methods like string and plastic sheeting to develop draw dies, creating full-size polystyrene models for reviews. Fast forward to today, and we have advanced forming simulation software that allows us to create virtual models of draw, controlled form, transfer, or progressive tools. These tools enhance our ability to predict outcomes with more accuracy. Presently, I would estimate that most software can confidently take us about 95% of the way towards achieving a feasible process and part. This advancement has significantly reduced the time required for discussions and agreements in review meetings. 

What does the future hold for metal pressing? 

The next evolution in press tool design lies in integrating current simulation software with tool design software, enabling automated tool design directly from final simulations with minimal human input. However, the question arises: how much human interaction is truly necessary for achieving this? Certain aspects, like tooling assembly and try-outs, will still require human expertise to ensure that tooling is fully prepared for production. 

Why did you choose to work with DeepForm, and what excites you about their solutions? 

While working with an OEM, I collaborated with the DeepForm team to explore the best applications for their technology. After much deliberation, I realized there were significant opportunities to apply this technology, particularly concerning a pressing issue we faced with a supplier’s part. DeepForm’s solutions align perfectly with various challenges, presenting numerous possibilities for cost savings and efficiency improvements. 

Which innovations or technologies in metal pressing do you think have most significantly impacted the industry recently? 

The most impactful developments over the last 25 years have been the integration of simulation software and advancements that enable quicker transitions from CAD to CAM. Additionally, the emergence of lightweight, high-strength steels has revolutionized designs, allowing manufacturers to use thinner gauges, which reduces overall weight and enhances product strength. 

Can you discuss the importance of quality control within the metal pressing process? 

Quality control is vital in the BIW (Body in White) manufacturing process, where fit and finish directly influence vehicle sales for OEMs. With high-strength materials, predicting spring-back becomes more complex. This is where simulation software becomes invaluable, enabling directional compensation before the actual manufacturing of press tools, thereby reducing try-out and machining time, which ultimately enhances quality and repeatability of BIW parts. 

How do you advise clients on balancing cost efficiency with maintaining high standards in their metal pressing operations? 

Traditionally, OEMs have focused on material utilization as the primary method for cutting costs. Historically, achieving about 55% utilization of the total BIW was the standard. However, with modern simulation software, we can develop better forming processes that enhance material utilization percentages. Streamlining part designs for easier pressing will also reduce costs and improve process efficiencies, such as minimizing the number of tools or stages required to produce a part. 

What role does collaboration between departments play in optimizing metal pressing processes? 

Collaboration among departments is essential, as it brings together subject matter experts who can design BIW parts that are feasible for manufacturing. This teamwork also supports effective production and quality control, ensuring that parts meet the required standards efficiently. 

Can you share any success stories where new techniques or tools in metal pressing brought tangible improvements for a client? 

I can recall working with an experienced tool manufacturing company when I first began using simulation software for BIW aluminum parts. During that time, I encountered challenges with parts that were initially deemed infeasible for manufacturing. Leveraging early simulations, we were able to identify and propose design changes to make the components more manufacturable. After implementing these modifications into the design, we collaborated closely with the tool manufacturing company to affirm that the new simulations could support the production of the redesigned part. Ultimately, we succeeded in persuading the subject matter experts at the toolmaker to proceed with tool design and manufacture, demonstrating the power of simulation in overcoming manufacturing challenges and enhancing feasibility.