In all areas of technology, the demand for high-quality, competitive and more valuable products is rising steadily. One approach to increase the value of manufactured products is the integration of electronic components in load carrying structures. These new products, which combine electrical and mechanical components synergistically, are called smart products. They consist of a passive structure and integrated electronics or smart materials. In addition to their mechanical properties they are also able to sense, to actuate or to transmit energy or data. The resulting product architecture requires both a mechanical and an electronic design in order to save subsequent assembly costs. Since further components are required to evaluate and control as well as to supply energy, all of those components need to be connected and integrated into the smart product. However, the main prerequisite for the marketability is the possibility of low-cost manufacturing and a robust mass production. Nowadays processes for the manufacturing of smart products do not fulfill the requirements for a sustainable mass production in a satisfying way as long as metallic structures are used. The authors deploy the forming technologies roll forming and sheet metal hydroforming to form sheets with applied flat electronics. Since the components are applied prior to the forming process, small and difficult to access installation spaces can be used effectively in the product architecture. The incremental bulk forming process rotary swaging is employed to integrate piezoceramics during the forming procedure without any additional joining elements. Challenges resulting from the chosen integrative manufacturing approach are the prevention of new kinds of failure modes and additional requirements for defined residual stress states. These challenges lead to extended process design requirements, which will be discussed in the paper in detail.

In metal forming a trend is observed towards increasing the performance of products by means of functional integration. One approach being pursued is the integration of electronic components. Multifunctional profiles with electrical conductors can transmit data and energy in addition to the mechanical function. They can be produced efficiently by roll forming. During the roll forming of multifunctional profiles wrinkles and cracks in the conductors may occur in the area of the contact of the rollers due to the contact normal stresses. In this paper, a design approach for multifunctional profiles preventing these failures in the tool contact area is presented and discussed on the basis of experimental and numerical investigations.