ORIGINAL RESEARCH New trends in sheet metal forming analysis and optimization trough the use of optical measurement technology to control springback G. L. Damoulis & E. Gomes & G. F. Batalha Received: 12 May 2009 / Accepted: 15 June 2009 / Published online: 1 September 2009 # Springer/ESAFORM 2009 Abstract The use of optical measurement equipment and software based on photogrammetry is becoming more affordable and is increasing their reliability in presenting results on surfaces topography as well as strain distribution. The question is, how feasible can their support be to the process/product development engineer in the choice of the right auto body-in-white (BIW) component design; how can they influence blank and tool geometries, process parameters and moreover the right material selection, in order to reduce the springback of such materials on drawing, reaching the required quality standards for the part. This paper describes some industrial cases on how these new techniques can be applied to lay out industrial deep drawing processes, accomplished by the use of optical measurement, improving design and process issues. Keywords Sheet metal forming . Optical measurement . Photogrammetry . 3D digitizing Abbreviations B Image plane C Principle distance R Rotation Matrix dx, dy Lens distortions x,y Image coordinate system x H Image coordinates of the principle point x P ,y P Image coordinate of projected object point P X,Y,Z Object coordinate system X*,Y*,Z* Support coordinate systems X O ,Y O ,Z O Object coordinates of the projection centre O X P ,Y P ,Z P Object coordinates of the observed object point P X P ,*,Y P ,*, Z P * Support coordinates of the object point P Introduction To reach the new market requirement targets for the auto BIW development, process integration from the early concept development phases to the start of production, must provide a streamlined scalable environment that encompasses every step in the process from early design feasibility to the process final validation. High safety standards, the high reduction in weight that improves fuel consumption, emissions and performance trends, a world class quality at reasonable production costs and schedule timing are changing the development chain in the automo- tive industry. Mainly regarding automotive lightweight construction based on the use of lightweight materials, meaning that building materials of low specific density and high-strength can be used, automotive engineers and designers are daily challenged, through the introduction of many new materials for their applications. Therefore, new design aims and methodologies should be developed [1, 2]. Auto BIW complaints usually involve complex geometry, irregular pressed parts from many different metallic G. L. Damoulis (*) : E. Gomes : G. F. Batalha Laboratory of Manufacturing Engineering, Department of Mechatronics & Mechanical Systems Engineering, Escola Politecnica—University of Sao Paulo, Av. Prof. Mello Moraes, 2231, CEP 05508.970 Sao Paulo, SP, Brazil e-mail: gdamoulis@uol.com.br URL: www.poli.usp.br/pmr/lefa E. Gomes e-mail: edsgomes@usp.br G. F. Batalha e-mail: gfbatalh@usp.br Int J Mater Form (2010) 3:29–39 DOI 10.1007/s12289-009-0413-0