Laser forming technology: a comprehensive review of mechanisms, process optimization, and industrial applications

Abstract Laser forming (LF) is an advanced non-contact manufacturing technique that utilizes laser energy to induce controlled thermal expansion and plastic deformation in metal sheets, enabling the shaping of high-strength and brittle materials with minimal residual stresses. The effectiveness of LF is governed by three primary mechanisms Temperature Gradient Mechanism (TGM), Buckling Mechanism (BM), and Upsetting Mechanism (UM)) which are influenced by process parameters such as laser power, scanning speed, beam diameter, and material properties. This review presents a comprehensive overview of recent advancements in LF, beginning with an analysis of the governing deformation mechanisms and their role in achieving precision and control. It then explores critical microstructural changes including grain refinement, phase transformations, and heat-affected zones (HAZ) that directly impact material behavior and performance. Building upon these foundational aspects, the article highlights current innovations in LF process enhancement through machine learning (ML)-based optimization, real-time thermal feedback, and adaptive control strategies. Challenges such as edge effects, residual stresses, and process repeatability are discussed, along with mitigation approaches Like forced cooling and adaptive scanning. Experimental findings show that forced cooling can increase the bending angle by up to 35.2% and improve energy efficiency by 22.14%. The review Further examines the application of computational models such as ANNs, SVMs, and GAs in predicting bend angles and optimizing process parameters. ANN-based models, for instance, have achieved prediction accuracies of up to 98.9%. The AI tools offer a holistic perspective on future research directions aimed at enhancing process sustainability and broader industrial adoption.