Bridging the gap between a digital design and a working press tool is one of the toughest challenges in sheet metal forming. As Head of Simulation and Project Delivery at DeepForm, José Azevedo ensures our innovative processes translate seamlessly to the shop floor.
In this Q&A, José discusses the realities of simulation, the limitations of standard industry tools, and how DeepForm is engineering its own solutions to overcome them.
What’s the role of CAD and simulation tools in modern sheet metal forming?
CAD and simulation tools are the bedrock of modern forming. We use CAD to map out die surfaces and blank shapes, then run virtual tryouts in simulation software. These tools predict thinning, springback, and potential splits before we cut any physical metal. Ultimately, it’s about solving formability issues digitally to save time and eliminate costly trial-and-error on the shop floor.
Where do off-the-shelf simulation tools fall short on the actual press shop floor?
The biggest gap is the disconnect between an idealized digital environment and physical reality. Standard tools assume uniform material properties, constant friction, and perfectly rigid presses, which rarely exist in production. Commercial software is heavily optimized for conventional deep drawing. If you introduce non-standard tool kinematics, off-the-shelf solvers struggle to predict material flow accurately, forcing engineers back to physical trial-and-error.
Why does this simulation gap make it so difficult to introduce new manufacturing techniques?
Inaccurate simulation creates risk. If a plant can’t reliably simulate a new die concept, they are forced to build expensive prototype tools just to prove it works. For innovative methods designed to reduce scrap or skip conventional drawing stages, this lack of reliable digital validation becomes a major bottleneck, delaying the rollout of more efficient processes.
How does DeepForm navigate these industry limitations when implementing our own technology?
Our fold-flow pressing relies on unique tool kinematics that standard simulation packages struggle to design efficiently. To solve this, we are developing our own software tools. By embedding our design capability into software, we can expedite the implementation of our die designs into customers’ existing lines with predictable, repeatable results.
How do you see the world of sheet metal evolving over the next few years?
I expect the whole industry to continue to push for cost efficiency, especially due to the wider adoption of casting within automotive bodies. I think the DeepForm technology is ideally placed to support this, as we provide a step change in material efficiency and improved formability which enables lower cost per part and a reliable forming process.
