ROBOFORMING: The Future of Metalworking? (I Had NO IDEA This Was Possible) - Smarter Every Day 290

The video begins with Destin from Smarter Every Day introducing the manufacturing deep dive series, focusing on a new process called incremental sheet forming, also known as Roboforming. This process, while not as fast or accurate as progressive metal stamping, allows for quick iteration and part creation, which is highly beneficial during development or for producing small quantities. Destin visits Machina Labs in L.A., where he meets Bobby, Ed, and Boback, the company's founders, who have backgrounds in software and materials engineering. They explain the process of shaping metal by using two tools, or end effectors, to apply force and deform the metal, similar to a potter working with clay. The process allows for complex geometries without the need for molds, reducing time and cost in certain scenarios.

In this segment, Destin and Mark from Machina Labs discuss the intricacies of controlling the robots used in incremental forming. They explain that the robots are not limited to KUKA but can also use Phanax, and that they've built their own control system from scratch. The process involves two robots, one pushing and one supporting, which allows for precise forming by localizing force between the tips. The robots are equipped with load cells to measure the forces applied and are programmed with a nominal trajectory that is adjusted in real-time based on continuous feedback. The conversation also touches on the challenges of dealing with the deflection of the robots under load and the complexities of motion control in such a dynamic system.

This paragraph delves into the specifics of the forces involved in the forming process, with up to 20,000 Newtons being applied. The challenge of maintaining precision under such high forces is discussed, as well as the need for the robots to adjust for deflection. The control loop uses force data to ensure accuracy, and the importance of the robots' stiffness in achieving precise forms is highlighted. The conversation also explores the concept of backlash in actuators and the impact of arm rigidity on the forming process. Ed explains the two types of accuracy: getting the robot to a specific point and maintaining accuracy while moving between points under changing forces.

Destin discusses the sponsorship of the episode by NordVPN, a virtual private network service that offers online privacy and security. After the sponsorship segment, the conversation returns to the topic of metal forming, specifically how the deflection of metal under force is managed. Destin uses a piece of fabric on a frame as an analogy to explain how metal behaves when pushed from different directions. The importance of boundary conditions and the effects they have on the accuracy of the final part are discussed. Ed and Mark explain how their software accounts for these factors to ensure the final product is close to the desired geometry.

The discussion continues with Destin and Mark exploring more complex forming operations, including forming on curved sections and working with non-planar surfaces. They describe how the robots can perform a continuous spiral operation, which is more efficient than layering planar slices. The conversation also touches on the different end effectors used for various forming tasks and the ability to switch between them seamlessly. The goal of creating a 'robotic craftsman' that can perform multiple tasks, such as forming, scanning, and trimming, is highlighted, along with the challenges of transitioning between these tasks and the importance of the tool changer system.

In the final paragraph, the conversation turns to the future possibilities of incremental sheet forming, particularly with difficult-to-form materials like titanium. The team at Machina Labs expresses excitement about the potential to form high-temperature alloys, which are crucial for hypersonic applications. They discuss the challenges of working with titanium and the need for elevated temperatures to make forming more manageable. The video concludes with Destin thanking the team at Machina Labs for their insights and expressing gratitude to the patrons of Smarter Every Day who support the series.