Reconfigurable tools and/or dies, reconfigurable inserts for tools and/or dies, and methods of use

A process for forming a first part with a defined geometry and a second part with a defined geometry different from the first part defined geometry using a reconfigurable tool and/or die set, the process comprising:

• forming the first part with the reconfigurable tool and/or die set, wherein the reconfigurable tool and/or die set comprises a shape defining surface comprising at least a portion formed of a shape memory material, wherein forming the first part with the reconfigurable tool and/or die set produces the first part with the defined geometry;
• activating the shape memory material to change the shape defining surface;
• and
• forming the second part with the changed shape defining surface to produce the second part with the defined geometry, wherein the second part defined geometry differs from the first part defined geometry.

A process for forming a first part with a defined geometry and a second part with a defined geometry different from the first part defined geometry using a tool and/or die set, the process comprising:

• inserting an insert into a tool and/or die set, wherein the insert comprises a shape memory material having at least one shape defining first surface adapted to change to a shape defining second surface in response to an activation signal, wherein the first and second shape defining surfaces have different geometries;
• contacting a blank with the insert and the tool and/or die set to form the first part with the defined geometry;
• activating the shape memory material to change the shape defining first surface to a shape defining second surface;
• and
• contacting an additional blank or the first part with the shape defining second surface of the insert and the tool and/or die set to form the second part with the defined geometry, wherein the second part defined geometry differs from the first part defined geometry.