Opportunities and challenges in metal forming for lightweighting: Review and future work

Jian Cao*, Mihaela Banu

*Corresponding author for this work

Research output: Contribution to journalReview articlepeer-review

35 Scopus citations


The purposes of this review are to summarize the historical progress in the last 60 years of lightweight metal forming, to analyze the state-of-the-art, and to identify future directions in the context of Cyber-physically enabled circular economy. In honoring the 100th anniversary of the establishment of the Manufacturing Engineering Division of ASME, this review paper first provides the impact of the metal forming sector on the economy and historical perspectives of metal forming research work published by the ASME Journal of Manufacturing Science and Engineering, followed by the motivations and trends in lightweighting. To achieve lightweighting, one needs to systematically consider: (1) materials and material characterization; (2) innovative forming processes; and (3) simulation tools for integrated part design and process design. A new approach for process innovation, i.e., the Performance- Constraints-Mechanism-Innovation (PCMI) framework, is proposed to systematically seek new processes. Finally, trends and challenges for the further development in circular economy are presented for future exploration.

Original languageEnglish (US)
Article number110813
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Issue number11
StatePublished - Nov 2020


  • Lightweight materials
  • Metal forming
  • Performance-Constraints-Mechanism-Innovation (PCMI)

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering


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