Exploring advanced micro-forming methods: Ultrasonic vibration (UV), pulsed current, and laser-assisted approaches

Abstract. The demand for micro-forming processes has grown due to the increasing need for miniaturization in electronics, medical devices, aerospace, and automotive industries. However, materials with high strength, corrosion resistance, and low weight often lack adequate formability at ambient temperature. Notable examples include titanium alloys, magnesium alloys, and aluminum alloys. Advancements in manufacturing technologies have made micro-forming more viable and cost-effective, leading to a higher demand for smaller and more intricate components. Emerging techniques such as electrically assisted micro-forming, laser shock micro-forming, and ultrasonic vibration-assisted micro-forming have been devised to overcome limitations associated with conventional micro-forming processes, offering enhanced precision, versatility, improved formability, and superior cost-efficiency. This article presents a comprehensive overview of state-of-the-art methods for the aforementioned emerging processes. It identifies existing research gaps, highlights future directions, and examines contact-related challenges in micro/meso-forming processes.