Metal Forming Processes: Overview and Benefits

Metal forming processes shape components without material loss. Instead of cutting or casting, a metal blank is plastically deformed into a new geometry – permanently, precisely, and with minimal waste. Especially for high volumes and high demands for strength and dimensional accuracy, forming processes are the more economical alternative to machining.

What metal forming processes are there?

Forming technology is a subfield of manufacturing in which a workpiece is deliberately shaped into its final form through plastic deformation. The main categories include:

Bulk Forming

Compression forming: Rolling, free forming, forging (open-die forging, die forging), pressing, extrusion.
Tensile-compression forming: Deep drawing, stretching, pressing.
Tension forming: Drawing out, deep drawing, widening.
Shear forming: Shifting, twisting.
Bending forming: Free bending, die bending, roll bending.
High-energy forming: Explosive forming, electrohydraulic forming (EHF), hydro impulse forming (HID).

Sheet Metal Forming (Sheet Metal Working)

Deep drawing
Bending
Edge bending
Punching

Procedure	Advantages	Disadvantages	Application
Cold forging	No material loss High strength High dimensional accuracy Very economical in series	Complex tool development Only for certain geometries	All types of components with different wall thicknesses and geometries, e.g., sleeves, rivets, connecting elements
Spin forming / spinning	Thin-walled parts Low tooling costs Suitable for small series	Limited to axisymmetric shapes More manual effort	Lampshades Housings Containers
Gearing by forming	Accurate gearings Can be combined with other processes	Special tools required Limited design flexibility	Gears Gearwheels Drive shafts
Deep drawing	Low material loss Ideal for cup shapes	Risk of cracks with unsuitable material Expensive drawing tools	Cans Battery cell housings Body parts

Advantages of Metal Forming Processes over Machining Methods

No Material Loss

The material is formed, not cut — resulting in maximum material utilization.

Higher Strength

Particularly durable and robust due to work hardening and intact fiber orientation

Economical for High Volumes

Once set up, the tools produce millions of uniform parts with minimal effort

Fast Cycle Times

Especially in mass production, significantly more efficient than, e.g., milling or turning

Functional Integration in a Single Part

Several component functions can be integrated into one part through targeted forming

Focus: Geometry Without Machining Cold Bulk Forming at Walter Schneider

Walter Schneider GmbH specializes in the chipless forming of complex geometries at room temperature and the forming of metal components at room temperature. We combine several processes into a cost-effective series solution – typically from around 50,000 pieces per year.

Our processes:

Forward extrusion – material flows in the punch direction, ideal for axes, bolts
Backward extrusion – for hollow, sheet-like components with high dimensional accuracy
Lateral extrusion – for creating lateral holes, ribs, or cavities
Multi-stage forming – combination of multiple directions and geometries
In-house tooling and prototyping

Contact

Whether you have an initial idea, a detailed drawing, or a finished part — we evaluate which metal forming process offers the best results for your project, including feasibility, cost-efficiency and scalability.