STRETCH ROLL FORMING

During the Phase I SBIR project funded by DLA, Fairmount Technologies (FT) has developed and proven a new CNC metal formingprocess called stretch roll forming (SRF) that can produce complex parts made out of extrusions without part-specific dies. The proofof-concept machine developed has stretch formed flat and T-section extrusions to geometry similar to that of aircraft parts.Recognizing the potential for this process to enable revolutionary manufacturing improvements, improve part quality, and save cost,Cessna Aircraft Co. and Spirit Aerospace, have worked with FT to identify part families and the manufacturing lines in which tointroduce the process, as well as requirements for successful forming of aircraft parts. In this Phase II project, FT proposes to designand build a prototype machine to meet these requirements and move the SRF process from a TRL of 3 to TRL 7. With our partnersinput, with the insights gained from further improvements to the proof-of-concept machine, by recruiting additional developmentpartners with complementary expertise, and by making the best use of phase II funds, FT will build a prototype SRF machine anddemonstrate that SRF can form parts to accurate geometry and with favorable properties.