GM has announced new aluminum processing technology

U.S. General Motors has announced a new type of aluminum plastic molding technology called Quick Plastic Forming (QPF). Using this technology, aluminum alloy processing will be simpler and more convenient, while also improving quality and saving fuel. The 2004 version of the Chevrolet Malibu Maxx uses a rear-slung rear panel machined with this technology.
QPF uses the blow molding technology commonly used in the aerospace industry. The processing process is as follows: The heated aluminum plate is placed in a heated metal mold and extruded using high-pressure air. If the original method of sandwiching an aluminum plate between two metal molds is used for extrusion molding, there is a drawback in that the shape is restored due to backlash. With QPF, complex shapes can be formed on different aluminum plates, and the processing time is also shorter. Metal molds can be made directly from design data. Since the molding process can be completed only by one-sided metal molds, the time for producing metal molds can also be shortened. Therefore, the development cycle can be shortened.
The original rear-striking back panel needs to weld the separately formed inner panel and outer panel, but by using a new technology, it can be integrally formed. In addition, the original rear lift back plate is 17.7kg (39lb). By using QPF aluminum processing, the weight can be reduced to only about 9kg (20lb).