The inefficacy of the conventional methods to form Aluminium Foam Sandwich (AFS) has led to the evolution of laser forming as an alternative. However, the current literature lacks studies that demonstrate the capability of the laser forming to form a targeted part out of AFS. The current study for the first time proposed a methodology and revealed salient factors relevant to laser forming an AFS panel into a prescribed scaled-down model (bumper beam). Estimation of the scan line position and the experimental methodology to obtain the desired process parameters against each scan line to obtain the targeted part are demonstrated. Chances of failure of the AFS part during the laser forming were investigated using finite element simulation. The laser-formed part that was finally obtained conformed well to the targeted shape and also exhibited improved flexural strength with no loss of local compressibility under the three-point bending test.
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