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Superforming

Superforming is a hot metal forming process that uses similar principles to thermoforming plastics, where a sheet of material is heated and forced onto a male or female form using gas pressure. The process is useful for producing complex surfaces. The technique was pioneered for use in alloy fighter jets, with a sheet of aluminum heated like "taffy" and then "blown" into a mold by a press system, allowing complex curves. It heats the sheets to 500 degrees Celsius, and after molding, vacuums out the air.

The Jaguar I-Pace was the world's first structure to be made with superforming. In 2015, McLaren announced that the 570S Coupe used superformed aluminum body panels. The first Morgan Aero GTs released in 2018 used the process. According to Bentley, the third-generation 2018 Bentley Continental GT is the first production car ever to have an entire body side made from the Super Formed process. The panels are "superformed" with heated aluminum sheets molded by gas instead of a stamp. In particular, the fenders, hood, and doors are superformed.

The superforming process varies mostly in the way that the metal is introduced to the form; the main 4 variations are:

Superforming process is used to create complex sheet geometries from a single piece of material and this process has been rapidly growing in many applications, including aerospace, automotive, buildings, trains, electronics, furniture and sculpture.

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