⚙️ Technical overview of the ShAPEretro system for improving manufacturing efficiency in metal extrusion
Pacific Northwest National Laboratory (PNNL) presents an innovative system for upgrading traditional extrusion presses, called ShAPEretro, which enables manufacturers to improve metal extrusion operations with higher energy efficiency and enhanced product quality without the need to replace existing equipment entirely.
This system is based on Shear Assisted Processing and Extrusion (ShAPE), which reduces energy consumption by heating the metal locally using shear friction instead of bulk heating, resulting in metal parts with superior properties and lower costs. ShAPEretro can be installed easily within existing presses, giving local industries the opportunity to benefit from this advanced technology without major capital expenditure.
🔧 The evolution of the ShAPEretro system
Metal extrusion is one of the oldest industrial technologies used to produce components such as aluminum tubes used in sports and automotive industries, as well as zirconium tubes in nuclear energy applications. Despite the importance of this technology, design and development processes in it have remained stable for decades, leading to increased energy consumption and limited progress in improving product quality.
The PNNL team took a different approach through Shear Assisted Processing and Extrusion (ShAPE), which uses the frictional force generated by shear movement inside the press to heat the metal precisely, without the need for bulk heating. This method provides better control, allowing the production of metal products with unique mechanical and physical properties while reducing energy consumption.
However, commercial challenges continued to hinder the wider adoption of ShAPE because of the financial and technical barrier associated with obtaining new presses designed specifically for it, which are often manufactured abroad and are extremely expensive.
🔥 How ShAPEretro works in existing presses
The idea of ShAPEretro began when researchers realized that traditional presses are equipped with a system called “die slide” that is used to replace dies easily. The laboratory leverages this predesigned system as an opportunity to install a new unit without radically changing the press.
ShAPEretro is integrated into the traditional press “die pocket” and adds a rotation axis capable of creating rotational shear movement for the die, making it possible to generate the shear phenomenon on which ShAPE technology depends.
This circular movement causes the metal to be heated through friction at the die level itself, which means:
- More precise localized heating.
- A significant reduction in energy consumption compared with conventional heating.
- Improved mechanical properties of the final products.
🏭 Practical trial and ShAPEretro performance
A prototype of the ShAPEretro insert was built and successfully tested on ShAPE 2, the largest multipurpose extrusion system at PNNL laboratories.
The initial tests focused on extruding aluminum tubes, and the results showed that the mechanical production quality was comparable to that produced by the full ShAPE system.
However, observations indicate that the system may not be suitable for all material or product types, which requires identifying the optimal applications.
PNNL laboratories are currently seeking collaboration with the industrial sector to develop a full ShAPEretro system and apply it to presses in a real industrial environment, which will enable optimal assessment and practical benefit.
🚗 ShAPEretro benefits for local industry and advanced manufacturing
The ShAPEretro system could open the door to a higher share of local extrusion presses, whose current utilization rate is only 50–60%. The system improves the optimal use of existing infrastructure with higher output and advanced quality solutions.
The benefits of the ShAPEretro system include:
- Lower energy costs and reduced consumption associated with intensive thermal processes.
- Improved properties of industrial components using 100% recycling of high-quality aluminum.
- Production of superconducting metal components used in power grids, supporting industrial sustainability and reliance on local materials.
- Flexible manufacturing solutions that allow make-to-order production through rapid die changes within the ShAPEretro system.
These advantages create real industrial opportunities to strengthen the local supply chain by recycling metal resources and reducing dependence on imports.
🏭 The future and ShAPEretro development opportunities
Funding for the development of the ShAPE system and ShAPEretro technology relied on research and development programs affiliated to the U.S. Department of Energy, including the Critical Minerals and Energy Innovation programs.
As development stages advance and industrial collaboration is expected, the opportunities for adopting ShAPEretro will expand across multiple industries, potentially changing the standards for manufacturing metal components and enhancing the flexibility of local manufacturing, especially in the automotive, renewable energy, and electronics sectors.
Once ShAPEretro becomes widely available, the benefits will extend to a large group of manufacturers that face material or capital constraints preventing them from adopting modern extrusion technologies.
🛠️ Conclusion
The ShAPEretro system represents an innovative step toward converting traditional extrusion presses into systems with high energy efficiency and product quality. By integrating rotational movement that generates localized shear heat, performance can be improved without the need for major investments in new equipment.
This initiative reflects the ability of mechanical engineering innovation to develop immediate, applicable solutions that support local industry and provide vital competitive advantages in a rapidly changing world.
📚 Related articles
Discover more from Mohdbali
Subscribe to get the latest posts sent to your email.
