A review and guideline on the recent development of ISF: system approach, process parameters, hybrid and heat-assisted processes

Incremental sheet forming (ISF) is a dieless metalworking technique that uses localised plastic deformation to incrementally deform a sheet of material at a small area until achieving a product of the desired dimensions without using large tools and dies unlike the conventional sheet forming process. ISF is more flexible and cost-effective. It is suitable for prototyping and small-batch production. However, the localised deformation during the process produces complex interactions of stretching, bending, and shearing posing challenges for process design and analysis. The process parameters and material properties significantly impact both the formability and dimensional accuracy of the products. These factors even further complicate analysis. Therefore, this paper presents a concise yet comprehensive review of a systems approach addressing the fundamental aspects of ISF, such as the process itself, material properties, deformation zones, tribology, process parameters, and the machinery employed. Additionally, it also explores hybrid incremental sheet forming (HISF) and applied heat-assisted enhancement of process capabilities. Finally, various potential applications are discussed providing an overview of their industrial utilisations and potentials. This review also aims to provide guidelines for overcoming the limitations of the ISF process and explore potential areas for future research to enhance its practical implementation.