Imagine a machine that folds metal like origami, creating curves instead of straight lines. Sounds like something out of a sci-fi movie, right? But this isn’t fiction—it’s the future of sheet metal manufacturing. Meet StilFold AB, a Swedish startup that’s revolutionizing the industry with what they call toolless industrial origami. And yes, their machine is affectionately nicknamed the ‘Stargate,’ thanks to its circular, portal-like design. But here’s where it gets really interesting: this process, known as curve forming, doesn’t just bend metal—it makes it stronger, lighter, and more efficient than traditional methods. But is this the end of conventional sheet metal forming as we know it? Let’s dive in.
Jonas Nyvang, CEO and co-founder of StilFold, explains that the inspiration came from origami. Unlike traditional sheet metal forming, which relies on straight bends, origami artists fold paper along curves and contours, creating intricate, strong structures. Nyvang and his co-founder, Tue Beijer, wondered: What if we applied this principle to metal? The result? A process that reduces the number of parts needed, simplifies manufacturing, and enhances strength—all while using thinner materials. And this is the part most people miss: curved folds distribute stress more evenly, preventing weak points and extending the material’s lifespan.
But here’s where it gets controversial: Can curve forming truly replace traditional methods like stamping or hydroforming? Critics argue that it’s slower and less suited for high-volume production. Yet, StilFold’s StilRide scooter proves otherwise. Initially designed with 15 sheet metal parts, the chassis now uses less than half that—and it’s made of stainless steel, weighing just 8.9 kg. This isn’t just a proof of concept; it’s a product on the market, winning international design awards.
The secret lies in StilFold’s software and machinery. Their StilWare CAD platform helps engineers design folds that maximize strength, while the StilTool CAM platform translates these designs into precise folding sequences. The Stargate machine itself is a marvel: three arms with angle-forming tools rotate to fold and compress the metal, creating curves with surgical precision. But here’s the kicker: the tools are interchangeable, allowing for customization based on material properties. Whether it’s stainless steel, aluminum, or even titanium, the machine adapts—though some materials, like certain aluminum grades, still pose challenges.
One of the most exciting aspects is the potential for simplification. Nyvang points out that curve forming eliminates the need for dedicated tooling, slashing the time from idea to prototype and production. But does this mean traditional tooling is obsolete? Not necessarily, but it does shift the focus from speed to efficiency. Instead of asking, ‘How fast can we make this part?’ manufacturers are now thinking, ‘How simply and efficiently can we make the entire product?’
StilFold is already installing its machines in European fabrication operations, with plans to offer fully equipped models globally by 2026. They’re also educating the next generation of engineers, partnering with institutions like Georgia Tech. But here’s the real question: Will curve forming become the new standard, or will it remain a niche innovation? Nyvang believes it’s about more than just technology—it’s about changing the way we think about design and manufacturing.
So, what do you think? Is curve forming the future of sheet metal manufacturing, or is it just a passing trend? Let us know in the comments below!
