Incremental sheet forming systems and methods for forming structures having steep walls

A method for forming a structure, the method comprising:

• forming a boundary region between an inner region and an outer region of a workpiece, wherein said forming comprises cutting a pattern between an inner boundary region curve and outer boundary region curve of the boundary region, wherein the pattern includes a plurality of openings and a plurality of connecting elements;
• supporting the workpiece on a die such that the boundary region conforms to a perimeter of a base of the die;
• performing, using a forming tool, one or more incremental sheet forming operations on the workpiece, wherein said performing is conducted after the boundary region pattern has been established;
• and
• removing the boundary region after said performing to form the structure.

A method of cutting a boundary region into a workpiece, wherein the boundary region includes a plurality of openings between a plurality of connecting elements, the method comprising:

• receiving, by a boundary region cutting tool, boundary region data indicative of the boundary region;
• operating, by the boundary region cutting tool, on the workpiece according to the boundary region data to provide the boundary region, wherein the boundary region comprises openings and connecting elements;
• supporting the workpiece having the boundary region on a die such that the boundary region conforms to a perimeter of a base of the die, wherein at least a portion of the boundary region is supported on the base of the die;
• performing, using a forming tool, one or more incremental sheet forming operations on the workpiece;
• and
• removing the boundary region after said performing to form the structure.