Research Project Information

Research Project Summary Information

Rapid Bending Capability for Titanium Sheet Metal(ST4719L-1)

DynaBil Industries Inc


DynaBil is a New York State based manufacturer of precision sheet metal components and assemblies for the aerospace industry specializing in hot forming titanium. An earlier NYSERDA sponsored project demonstrated laser bending of titanium sheet metal. The process was shown to be both controllable and predictable using sophisticated empirically and FEA-based models. Unfortunately, the resulting material microstructure around the laser scan line is unacceptable by aerospace industry standards. Although the laser bending process cannot be adopted in its present form, the new modeling and analysis tools developed as a result of the laser bending project will be invaluable for making significant improvements to the existing hot forming process. DynaBil currently uses the hot brake forming process, a standard industry practice to fabricate titanium sheet metal parts. This process heats up the titanium work piece of around 2 lbs in an open die set-up of 4,000 lbs in mass.

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Project Description

The contractor, with the assistance of the RPI CAT, will (1) improve the hot brake forming process; (2) design, develop and demonstrate an automatic backstop adjustment; and (3) investigate alternative heating methods for hot brake forming of titanium, namely electrical resistance and induction heating.


Optimization of the hot brake forming process, automation of the backstop adjustment, and implementation of more efficient titanium heating methods have the potential to (1) decrease energy consumption by 70% for an approximate annual energy savings of $25,000, which will increase proportionally with increased sales; (2) decrease processing time by 50%; (3) increase part throughput by 100%; and (4) increase sales due to improved cost competitiveness, producing a growth estimate of 10-15% per year. DynaBil is estimating that employment will grow from 115 currently to 159 by 2001 and 184 by 2003, 50% of this projected growth can be attributed to the success of this project.

Project Results

For certain parts made by DynaBil, either electrical resistance or induction heating looked to be promising technologies based on this study. For some smaller parts with simple shapes, the electrical resistance heating appeared promising, while for larger complex shaped parts, the induction heating approach looked promising. Still, the lack of available equipment in the marketplace (that would not require site specific engineering cost) prevented DynaBil from adopting the technology.


DynaBil Industries Inc
PO BOX 810
Coxsackie, NY 12051

Principle Investigator

Ron Miller

Universities Involved

Rensselaer Polytechnic Institute


Project Type:

Research Study

Technologies Types:

Industrial Products

NYSERDA Contact Information

William Reinhardt


R&D - Mfg Tech & On-Site Pwr

Contract Details

Start Date: 1/11/2010
Project Status: Active
Contract Number: ST4719L-1

Last Updated: 12/23/2010