Method for forming a metal beam or stringer

A method of bending a metal beam having a shear center and at least one principal axis to provide a deflected metal beam, the method comprising:

• (a) clamping a first portion of the metal beam in a substantially fixed position;
• (b) clamping a second portion of the metal beam in a position whereat the metal beam is rotatable about three axes in reaction to a bending force applied thereat;
• (c) applying a net bending force to the clamped second portion of the metal beam at a predetermined angle by an actuator;
• (d) sensing twisting of the second portion of the metal beam resulting from applying the net bending force by a laser sensor;
• and (e) modulating the angle at which the net force is applied in a direction that reduces the twisting of the metal beam, whereby the net bending force is moved toward the shear center and toward being along the principal axis of the metal beam, wherein the applying a the net bending force to the clamped second portion of the metal beam includes applying a first bending force in a first direction and applying a second bending force in a direction that is substantially perpendicular to the first direction of the first bending force, and wherein the sensing twisting and the modulating the angle at which the net bending force is applied to the metal beam includes:
• sensing twisting of the second portion of the metal beam resulting from applying the first and second bending forces;
• and translating the first bending force in a direction that is transverse to the first direction and that reduces the twisting of the metal beam, wherein the first bending force is applied to the clamped second portion of the metal beam in a horizontal direction;
• the second bending force is applied to the clamped second portion of the metal beam in a vertical direction;
• and the first bending force is translated in a vertical direction that reduces the twisting of the metal beam.