ProfessorMatthias Weiss

Research Interests:

Sheet Metal Forming and Material Modelling:
Matthias has over 20 years of sheet metal forming experience and has established at IFM, Australia`s only sheet metal forming research laboratory which includes an Erichsen sheet metal testing facility complimented with two Digital Image Correlation (DIC) strain analysis systems. Matthias works closely with IFM`s Metal alloys research group to understand microstructure effects on the sheet formability and to develop advanced material models for forming process design and analysis.

Roll Forming and Flexible Roll Forming:
Matthias is Australia`s leading roll forming specialist. His research in this field combines advanced test methods for material and process monitoring with innovative solutions for quality control. While his initial work aimed at establishing a fundamental understanding of material behaviour in roll forming, more recent work has focused on new concepts for AI and machine learning supported quality control and the development of new roll forming technologies to suit Australia`s demand for advanced building products and low-cost manufacturing. In 2017 Matthias has established, at Deakin University, a world first flexible roll forming prototyping facility. In flexible roll forming the forming rolls are no longer fixed in space but can follow complex part contours which allows production of structurally optimised component shapes. Initial focus has been on forming high strength steels for the automotive industry while future aim will be on forming heavy sections from thick metal plate for bus, train, truck, and defence vehicle applications.

Advanced Manufacturing:
As the Co-founder of FormFlow Matthias has commercialised a world-first forming technology for producing sharp corners in corrugated sheet profiles. The new forming concept applies the Origami principle of paper folding to sheet metal forming and, in this way, reduces material deformation to simple bending. Current research aims to establish a fundamental understanding of material deformation in the process and based on this to develop solutions for quality control to enable technology scale up. While the current technology is aimed at sheet metal products for the building and construction sector, future work will be directed towards the manufacture of battery casings and crash components for the automotive industry.

Micro forming and green hydrogen technologies.
The Deakin Hycel Technology Hub has established, at Warrnambool, Australia-first capability for the testing and optimisation of new fuel cell technologies to accelerate Australia`s transition to green hydrogen. Matthias is working closely with the Hycel team and industry to develop solutions for rapid prototyping of micro metal components that are required for fuel cell stack testing at industrial scale. Future work is aimed at applying the new rapid prototyping approach to develop and test new micro forming technologies for low-cost mass production.

Affordable and resilient housing solutions.
Matthias is working closely with the building and construction industry and research groups in architecture and civil engineering at Deakin University to develop new manufacturing and building product solutions to address Australia`s need for affordable housing. Aim is on building prefabrication and modular design, Life Circle Analysis (LCA) and new ownership models to reduce waste and cost and enable a circular economy in housing.

Projects and Partnerships.

• Regional Precincts and Partnerships Program (RPPP)- Stream 1: Precinct development and planning “Colac Otway Adaptable Precincts: a blueprint for future housing delivery” - $2Million (2024 – 2025). Partners: University of Wollongong, FormFlow, Urbis, the Colca Shire, Bushfire Building Council of Australia, Kids Under Cover, John Lyng Group, the Salvation Army Australia, Loddon Mallee Housing Services.

• Cooperative Research Centres Project (CRC-P) “A new fire rated wall panel system for commercial and residential construction” -$2.27Million (2024 – 2026). Partners: SpeedPanel, FormFlow.

• Baosteel Australia Joint R&D Centre (BAJC) “Intelligent in-line flexible roll forming shape control for Electric Vehicle (EV) component production” - $250k (2023 – 2025). Partners: Baoshan Iron & Steel Co.,LTD.

• Australian Research Council Linkage Project (ARCLP) “Metal folding fundamentals to shape new corrugated building products” - $352k (2021 – 2025). Partners: FormFlow.

• Hysata industry-direct-funded project “A Forming technology to produce bipolar plates for Alkaline Electrolyser cells, 2nd Project” -$322k (2023 – 2025). Partners: Hysata.

• Future Energy Exports CRC Limited (CRC Entity) “Feasibility of open source fuel cell stacks with different hydrogen storage options”, - $97k (2024 – 2025). Partners: University of Western Australia, TU Chemnitz, Germany.

• The City of Greater Geelong Clean Economy Grants “A new finance model to investigate circular economy in housing”, - $25k (2024). Partners: FormFlow, Anvarta.

• Innovation Connections (IC) Project “A first Australian made K40 crash rated fence system – Stage 2”, -$100k (2023 – 2024). Partners: Doogood.