How Advanced Servo Press Technology Enhances the Forming & Bending of Complex Geometries

In automotive manufacturing, forming complex geometries is critical to producing lightweight, safety-critical components that meet stringent industry standards. These intricate designs play a central role in structural integrity, performance and vehicle safety.

Achieving these geometries with traditional mechanical and hydraulic presses can introduce limitations, particularly when working with thin-gauge or high-strength materials. This is where advanced servo press technology excels — offering control, precision and repeatability during forming and bending processes.

At ATD, we leverage servo press technology to create intricate brackets, reinforced housings and underbody components that maintain tight tolerances and superior quality. In this blog, we’ll explore the role of complex geometries in automotive design and how ATD’s servo press expertise ensures exceptional results.

The Role of Aluminum in Automotive Lightweighting Why Complex Geometries Are Essential In Automotive Manufacturing

Meeting Safety Standards

Safety-critical components must meet strict structural requirements to ensure crash performance and occupant protection. Complex geometries allow manufacturers to design parts that deliver exceptional strength without excess material or weight.

Examples include:

• Seating brackets
• Door lock mechanisms
• Underbody reinforcements

Improving Vehicle Performance

Components with complex designs help optimize vehicle performance by reducing vibration and improving driving comfort.

Examples include:

• Reinforced housings
• NVH (noise, vibration and harshness) reduction components

Benefits include:

• Reduced noise and vibration
• Enhanced structural stability

Supporting Lightweighting Goals

Lightweighting plays a key role in improving fuel efficiency for traditional vehicles and increasing range for electric vehicles (EVs). Complex geometries enable the use of thin-gauge materials (≤ 2.5 mm) without sacrificing strength or durability.

Example applications include:

• Underbody components
• Structural brackets

accommodating Advanced Materials

Modern automotive manufacturing relies on advanced materials to balance strength, weight and cost. These include:

• High-strength, low-alloy steels
• Aluminum alloys
• Galvanized steel
• Dual-phase materials

Complex geometries maximize the material properties of these metals, allowing for improved strength-to-weight ratios, durability and corrosion resistance.

Applications Requiring Complex Geometries

1. Underbody Components
   Brackets, housings and reinforcements designed to withstand harsh conditions and deliver long-term durability.
2. Interior Brackets
   Structural components requiring strength, precision and consistency.
3. Seating Systems
   Safety-critical parts designed to exact specifications for crash performance and occupant protection.

Why Servo Press Technology Excels in Forming Complex Geometries

Advanced Control & Precision

Servo presses provide programmability and variable stroke speeds, giving manufacturers greater control over material flow, bend angles and forming forces. This flexibility allows for the precise creation of intricate shapes while minimizing defects like wrinkling, tearing or springback.

Unlike traditional mechanical and hydraulic presses, servo presses offer customizable stroke profiles, making them ideal for forming complex geometries.

Repeatability & Efficiency

Servo press technology ensures consistent, repeatable results for applications requiring tight tolerances. Processes like flanging, coining and embossing benefit from this level of precision, allowing manufacturers to produce high volumes with minimal variation.

Key advantages include:

• Reduced material waste
• Improved Product Quality

ATD’s Approach to Forming Complex Geometries with Servo Press Technology

Die Design & Tooling Innovation

ATD combines advanced servo press capabilities with custom die designs optimized for precision forming. Our dies are engineered to deliver uniform material flow and maintain precise geometries, even with challenging materials like aluminum and galvanized steel.

Material Flow Control

Servo press settings — such as stroke profile, force application and speed — allow ATD to control material flow during forming, flanging and bending processes. This ensures precise geometry while avoiding defects like tearing, wrinkling or uneven thickness.

Processes Enabled by Servo Press Technology

• Blanking: Produces clean, precise cuts with minimal burrs, ensuring parts meet exact specifications.
• Embossing: Creates functional and aesthetic surface details for components requiring precision.
• Flanging & Bending: Achieves tight bend radii and consistent angles for structural brackets and reinforcements.
• Coining: Forms high-strength materials to exact tolerances for safety-critical parts.

ATD’s Competitive Edge With Advanced Servo Press Technology

Integration of Multiple Processes

ATD combines servo press operations with secondary processes like roll forming, welding, riveting and sub-assemblies. This integration streamlines production, reduces lead times and ensures higher overall quality.

Industry Versatility

While automotive manufacturing remains a core focus, ATD also serves sectors such as:

• Heavy trucks
• Aerospace
• Plumbing and industrial hardware
• Electrical components

Efficiency & Sustainability

Servo press technology minimizes material waste and improves production efficiency, helping manufacturers meet sustainability and cost-saving goals.

Why Choose ATD for Complex Geometries Stamping?

Expertise in Advanced Processes: ATD’s mastery of servo press technology — supported by in-house die design and process engineering — ensures high-quality, precise results for even the most challenging geometries.

Proven Track Record: As a trusted partner for OEMs and Tier 1 suppliers, ATD consistently meets the stringent quality requirements of safety-critical and lightweight applications.

End-to-End Solutions: From design consultation to advanced forming and value-added assemblies, ATD delivers comprehensive solutions tailored to customer needs.

Key Takeaways

Servo press technology is essential for forming and bending complex geometries that meet modern, automotive design goals. ATD’s expertise in die design, material flow control and advanced forming processes ensures precise, repeatable results for lightweight and safety-critical components.

Looking to produce intricate, high-performance parts? Contact ATD today or request a quote to learn how our servo press capabilities can optimize your next project.