Zero scrap manufacturing methods for metal containers, and associated tooling

A can body tooling assembly, the can body tooling assembly comprising:

• a closing punch structured to mount a cylindrical can body and comprising a circular base and a cylindrical support extending from the circular base;
• a folding die, the folding die comprising a first solid body formed with a fold-forming cutout at a can receiving end;
• a closing die, the closing die comprising a second solid body formed with an end-flattening cutout at a can receiving end;
• and
• a friction stir welding tooling assembly, the friction stir welding tooling assembly comprising:
• a headstock;
• a stirring tool comprising a planar welding surface and coupled to the headstock in a manner that enables the stirring tool to rotate relative to the headstock;
• and
• a can stabilizing arrangement structured to hold the can body fixed in position such that a flattened end of the can body faces the welding surface,
• wherein the fold-forming cutout is convex such that a concave fold-forming surface is formed in the interior of the first solid body.

A container body, the container body comprising:

• a first end comprising a planar edge;
• and
• a second end disposed opposite the first end,
• wherein the second end forms a planar base comprising a plurality of triangular formations welded together.

A method of manufacturing a body of a container, the method comprising:

• providing a metal strip;
• winding the strip into a tube;
• between a first end of the tube and a second end of the tube opposite the first end, alternating between cutting along a zigzagged path and cutting along a planar path to produce a plurality of can bodies, with a first end of each can body comprising a planar edge and a second end of each can body comprising a plurality of triangular formations, each triangular formation comprising an apex;
• for a given one of the can bodies, forming a folded end by folding all of the triangular formations toward a central axis of the given can body until each apex coincides with the central axis;
• for the given one of the can bodies, forming a flattened end by flattening the folded end;
• and
• for the given one of the can bodies, friction stir welding an entire external surface area of the flattened end at one time.