One-Step Blank Design & First Manufacturing Insights

Fast, early-phase assessment using one-step/inverse forming to determine the optimal blank and provide the first manufacturability read before investing in detailed die design. You get material usage, likely risk zones (thinning/FLD/wrinkling), and an initial “press/recipe” direction to align design, purchasing, and tooling teams.

When to use

• RFQ and concept freeze decisions

• Early DFM with styling or packaging constraints

• Costing and sourcing comparisons between vendors/materials

• Gate reviews before moving to full process design

Technical scope

• Blank development: perimeter, add-stock, pierce allowances, DXF output.

• Nesting & utilization: coil width scenarios, yield %, cost/part estimate.

• Deformation maps: FLD, thinning, draw-in trends, wrinkling tendency.

• Sensitivity checks: thickness/material grade options (e.g., CR4–DP/LAS/Al), friction/lube assumptions.

• First press insights: indicative tonnage/energy, binder concept, draw-bead candidate regions.

• Risk register: areas likely needing radii changes, add-ons/supports, local reliefs, or process staging.

• Springback read (screening level) and GD&T notes for critical surfaces.

Deliverables

• Simulation Report (PDF):

  • Executive summary and recommendations for next gate.

  • Blank contour, nesting layouts and utilization %, cost/part estimate.

  • Maps: FLD, thinning, wrinkling tendency, draw-in overview.

  • First “press recipe” suggestions (binder range, candidate bead zones, friction target).

  • Risk & countermeasure shortlist to carry into detailed process design.