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Design and Development of a Hydrostatic Support Device for Hot Incremental Sheet Forming of PMMA

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Abstract:

Thermoplastic-based sheets (TBSs) are increasingly adopted in the automotive and aerospace sectors due to their potential for producing lightweight and durable structures. However, conventional manufacturing techniques, such as compression molding, offer limited process flexibility, as they rely on costly, dedicated molds. Single Point Incremental Forming (SPIF) represents a promising die-less alternative. Nevertheless, its application to thermoplastics requires strict control of the process conditions to avoid material failure. This study focuses on the validation of a novel experimental apparatus for pressure-assisted hot SPIF. The developed equipment enables precise, real-time control and regulation of both the working temperature and the hydrostatic support pressure, which are critical parameters for enhancing polymer formability. A key aspect of the experimental procedure is the use of an aluminum sacrificial sheet placed between the forming tool and the polymeric blank. This intermediate layer fulfills a dual role by ensuring a hermetic hydraulic seal to prevent fluid leakage and by promoting uniform pressure distribution during the forming process. The experimental results demonstrate the effectiveness of the proposed setup, achieving successful deformation of TBSs with high geometric accuracy. Overall, this research confirms the feasibility and robustness of the designed equipment for processing unconventional materials, offering a flexible and efficient alternative to traditional rigid tooling technologies.

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Periodical:

Solid State Phenomena (Volume 389)

Pages:

59-64

DOI:

https://doi.org/10.4028/p-5nnEHa

Citation:

Cite this paper

Online since:

April 2026

Authors:

Romina Conte*, Stefano Trimarchi, Francesco Gagliardi, Luigi De Napoli, Giuseppina Ambrogio

Keywords:

Hot Forming, PMMA, Single Point Incremental Forming, Thermoplastic

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Creative Commons CC BY 4.0

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* - Corresponding Author

References

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