Quick Plastic Forming (QPF) Process
In 2004, GM’s Materials and Processes Lab announced a new aluminum forming process that provides improved styling flexibility, easier assembly, higher component quality and improved fuel economy. The single-step process, called quick plastic forming (QPF), allows GM to make more complex forms for production models – eye-catching shapes previously limited to concept or low-volume niche vehicles. GM’s QPF process is designed to produce more than 100,000 parts per year.
GM adapted QPF from a hot blow forming process used in the aerospace industry. Aluminum formed with the QPF process debuted on the 2004 Chevrolet Malibu Maxx liftgate, cutting the liftgate’s weight from 39 pounds to 20 pounds, and reducing manufacturing time while maintaining exceptional safety ratings. GM has more than 40 patents on QPF technology.
GM received the 2006 Nano 50TM Award, sponsored by Nanotech Briefs, recognizing the top 50 innovations impacting the commercialization of nanotechnology into mainstream market. We’ve also been recognized by the Society of Plastics Engineers and the American Chemical Society.
How it works
In the traditional stamping process, sheet metal is deformed between two dies in a heavy press, causing the metal to conform to the shape of the dies. Because aluminum is less rigid than steel, aluminum stampings can be prone to spring back to their original shape.
With QPF, a heated aluminum sheet is subjected to high-pressure air that makes it conform to the shape of a hot tool. The high temperature improves the formability so that even complex shapes can be manufactured. Dimensionally correct panels are possible because aluminum “spring back” is eliminated. The QPF process is math-based, with the dies created directly from design data. Simpler, one-sided tooling also reduces development time and shortens the all-important vehicle development process.
2007 Model Availability [2008 Coming Soon]
| Cadillac | STS |
Download in MS Powerpoint format [.ppt]: QPF Images [2.94mb]
QPF images on GM Media Online Catalog [GM photography requires a valid GM Media Online ID and password.]