Metamorphic manufacturing: More sustainable metalwork

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  Quantumrun Foresight
• October 18, 2023

Insight summary

Robotic blacksmithing, also known as metamorphic manufacturing, uses advanced algorithms and machine learning to shape metal with high precision, offering a more sustainable alternative in metal manufacturing. The technology heats and shapes metal without casting or machining, closely mimicking human blacksmithing but with greater efficiency and accuracy. Compared to traditional methods like CNC machining, which can waste up to 90% of material, or 3D printing, which has limitations in material strength, robotic blacksmithing generates less waste and can produce stronger, more heat-resistant components. 

Robotic blacksmithing context

Metamorphic manufacturing, also known as robotic blacksmithing, enables machines to shape and form metal without casting or machining. Like human blacksmiths, the mechanical counterparts repeatedly shape the metal until it reaches the desired form, using sensors to decode the shape of each part, lasers to heat the metal, and a press with interchangeable tools to apply force to the necessary areas. By slowly altering the shape of the metal and using heat as needed, the robotic blacksmith can achieve the desired microstructure without adding or subtracting anything from the original material.

A team of undergraduates from Ohio State University showcased this metalworking technique as part of a challenge presented by Lightweight Innovations For Tomorrow (LIFT), a government-funded organization. They enhanced a computer-controlled milling machine with hardware and software, enabling it to perform controlled deformation. Professor of Materials Science and Engineering Glenn Daehn describes metamorphic manufacturing as the third wave of manufacturing. 

The first wave, known as computer numerical controlled manufacturing (also called CNC machining or subtractive manufacturing), is considered wasteful and time-consuming, as only a fraction of the material is utilized. In fact, up to 90 percent of a metal block may be carved away. The second wave, which involves 3D printing or additive manufacturing, also generates waste. Additionally, the cost of raw materials, such as metal powders and equipment, can be a barrier to entry.

Disruptive impact

Each manufacturing method has its benefits and potential drawbacks. Although 3D printing has greatly benefitted manufacturers, it has some limitations. Objects created through additive manufacturing are typically weaker and more prone to deformation under high temperatures. Additionally, it's impossible to modify the microstructure of metal objects produced via 3D printing, as the final product is built layer by layer. Human blacksmiths can't work around the clock, create identical parts with precision or craft components on a large enough scale for use in airplanes or spacecraft.

In contrast, robotic blacksmithing can create vital parts with higher heat deflection temperatures without requiring specially adapted materials like 3D printing. The repeated manipulation of the metal can achieve desired properties in the final product, such as tempering steel to enhance its resilience. This method generates less waste as it doesn't involve removing any material. Additionally, since robots carry it out, the process can operate continuously, producing large objects in one solid piece without the need for welding or bolting multiple parts together, reducing the risk of weak points. Consequently, it's becoming a feasible alternative to many of the current metalworking technologies in use.

Implications of robotic blacksmithing

Wider implications of robotic blacksmithing may include: 

• Lower costs and higher profits for companies involved in robotic blacksmithing. This trend could also create new job opportunities for individuals with skills in robotics and automation.


• Reduced labor costs and decreased demand for human blacksmiths, leading to potential job losses and shifts in the labor market.


• The reduced demand for human blacksmiths leading to the decline of traditional blacksmithing skills and knowledge, potentially leading to the loss of cultural heritage in manufacturing towns.


• Faster manufacturing turnaround times and increased production output. 


• Fewer workplace injuries and accidents, resulting in safer working conditions for employees.


• Increased investment into manufacturing research and development, potentially leading to increased government spending and shifts in research priorities.


• The shift towards automation and robotics requiring retraining for workers in industries impacted by these changes, potentially leading to additional costs for companies and governments.

Questions to consider

• What are some potential drawbacks or limitations of robotic blacksmithing?


• What other industries could benefit from the use of robots in manufacturing?