Ohio State Pioneers 'Metamorphic Manufacturing' for Complex Shapes
Ohio State University is pioneering a revolutionary manufacturing process called 'metamorphic manufacturing'. This method, led by Professor Glenn Daehn, combines elements from blacksmithing and robotics to create objects through incremental changes using plasticine as a hot metal surrogate and open-die forging.
The process involves sensors evaluating each part's shape and microstructure, with heat added through lasers or force applied by robotic arms for shaping. This allows for close material tailoring, enabling complexly shaped products with controlled geometry and local properties.
Elon Musk, a prominent figure in the tech industry, believes that 'machines that build the machines' are more important than the products they manufacture. This perspective aligns with the potential of metamorphic manufacturing, which could theoretically produce a Cybertruck of any shape in the near future. Currently, the term 'metamorphic manufacturing' is not widely recognized, but related research in cyber-physical systems and digital twins is ongoing at institutions like the University of Innsbruck.
Professor Daehn believes this process is less time-consuming and less expensive than other types of digital manufacturing. It could potentially supersede current technologies like additive manufacturing and CNC machining due to its sustainability and ability to operate 24/7.
Metamorphic manufacturing, or 'robotic blacksmithing', is poised to become the third wave of digital manufacturing, following CNC machining and additive manufacturing. The study on this process serves as a theoretical framework to encourage scientists and engineers to develop the technologies that will enable this new manufacturing revolution.
