Agile manufacturing of a micro-embossed case by a two-step electromagnetic forming process

A very agile method, that relies solely on simple single-sided tooling, to form open-box-like enclosures with surface detail such as highly embossed surface features is demonstrated and analyzed. For example, this method may be used to fabricate personal electronics cases. The technique uses electromagnetic forces in a two-step process. In the first step a newly developed uniform pressure electromagnetic actuator is used to make a micro-embossed pre-form that can contain very fine surface detail in the part by micro-embossing features in the forming die. This blank is then trimmed. In the second major step electromagnetic flanging is used to give greater depth and steeper walls to the case. Both electromagnetic operations use one-sided tooling and very light equipment. In principle the tooling needed for this type of process can be put to use within days or hours of finalizing the component design and precise tooling tolerances or precise alignment are not required. This work shows the essential feasibility of this approach to manufacturing either small or large lots of components.