Many sheet metal components appear simple, but achieving stable production requires careful control of material flow, blank holding force, forming geometry, springback, and tooling design.

This project involved the complete development of a sheet metal forming system, from product development and forming strategy through tooling design, manufacturing, tryout, and production implementation.

As project lead, I was responsible for product engineering, process development, tooling design, manufacturing support, and production validation. The tooling combined blanking and forming operations within a single system to improve production efficiency while maintaining dimensional consistency and part quality.

The project required balancing manufacturability, tooling durability, production repeatability, and cost efficiency to ensure reliable mass production.

Projects like this are where product development, tooling engineering, and manufacturing execution come together.