November 2025 Volume 7

MEMBERS SPEAK

FROM SHOP FLOOR TO CLASSROOM Forging in Scaled Form By Bailey Taylor

F orging is one of the oldest manufacturing processes, shaping parts that are essential to industries like aerospace, automotive, and energy. Despite its importance, it can be a challenging concept for students to grasp. Unlike welding or machining, where results are visible almost immediately, forging relies on material flow under high pressure. Without a hands-on example, these concepts can remain abstract and difficult to visualize. The Forging Industry Educational and Research Foundation (FIERF), the educational arm of the Forging Industry Association (FIA), works to bridge that gap. Its mission is to advance forging education, support research, and connect students with opportunities in advanced manufacturing. The goal is to help the next generation gain both knowledge and excitement about the forging industry. Recently, FIERF developed a project aimed at bringing forging directly into classrooms through scaled, interactive teaching tools. These kits let students experience a simplified version of the forging process. By combining hands-on activities with accurate technical representation, the project makes forging approachable and engaging for students who might otherwise have little exposure to manufacturing. EST Tool & Machine, Inc. was happy to get the opportunity to contribute to the initiative by providing 3D-printed scale dies, a model forging press, and authentic footage of machining and CAD/CAM processes. While FIERF guided the vision and overall design, EST Tool’s role was focused on technical support and ensuring the educational models reflect real-world tooling. FIERF’s Hands-On Approach The project is based on a simple principle: students learn best when they can directly interact with concepts. Forging typically requires massive presses, extremely hot metal, and complex dies. Obviously, these conditions aren’t safe or practical for classrooms. FIERF addressed this by scaling down the process, allowing students to see forging in action without industrial equipment. Each kit includes sets of scale dies and a model forging press. Students use play-doh or modeling clay as a stand-in for heated metal. When they press the material between the dies, they can observe how it takes the shape of the die cavity. Activities like this make ideas such as material flow, cavity design, and forming forces much more tangible. Through this interaction, students also begin to appreciate that every forged part is the result of careful tooling design. That’s where EST Tool’s technical support comes in. EST Tool’s Contribution At EST Tool, we specialize in designing and producing tooling for the forging industry. Supporting FIERF’s project presented an opportunity to share expertise and provide scale models that demonstrate real-world manufacturing principles.

Working closely with FIERF, we produced several sets of 3D-printed scale dies that replicate the geometry and features of industrial tooling. A 3D-printed forging press model helps students understand how dies and presses interact in practice. These physical models provide a hands-on experience that makes abstract concepts more accessible. To complement the models, we also machined scaled aluminum dies in our shop. While these will be available for the students, this was not their main goal. Instead, they provided authentic footage of the CAD/CAM programming and CNC machining processes. By showing students how tooling moves from digital design to physical production, the media reinforces the connection between concept and execution. Combining the 3D-printed models with machining footage allows the kits to demonstrate both the tools and the processes behind them. This dual approach gives students a more complete understanding of modern forging technology. Technical Considerations Even though the project is designed for younger students, maintaining technical accuracy was important. These models are teaching tools, not toys, and reflect real engineering principles. Key design considerations include: • Draft Angles: Proper draft angles show how forged parts are designed to release from dies. • Parting Lines: Students can clearly see where dies separate, illustrating an essential aspect of tooling design. • Flash Allowances: Small allowances demonstrate how excess material is managed and trimmed in actual forging. • Scaled Geometry: Dimensions are proportional to real industrial tools, providing a realistic reference while remaining classroom-friendly. These details help students understand why tooling is designed a certain way and how engineers consider material flow, geometry, and efficiency. For many students, this may be their first exposure to real engineering logic.

FIA MAGAZINE | NOVEMBER 2025 64