4/23/2026
Speira × TOUMI Redefine the limits of aluminium forming
Aluminium Pillows Engineering Form Without Limits
When visionary design meets advanced material expertise, new possibilities emerge. In collaboration with TOUMI, Speira helped bring an unconventional idea to life: sculptural Aluminium Pillows, formed entirely without molds or dies - using only internal air pressure.
The ambition was clear: create complex, three‑dimensional aluminium shapes from two flat sheets, relying solely on material performance and engineering precision.
The Challenge: Forming Without Tools
Tool‑free metal forming pushes aluminium to its physical limits. The pillows required extreme deformation, multi‑directional stretching, and flawless surface quality — all without traditional forming tools. As Prof. Dr. Thomas Ummenhofer explains, the goal was to shape aluminium purely through controlled air pressure. Early prototypes proved the concept, but also revealed the material limits. A new solution was needed.
The Solution: VERSA Form 1050
Speira identified VERSA Form 1050 as the ideal foundation, an alloy already known for exceptional formability. Together with TOUMI, the alloy was further developed to meet the demands of extreme deformation while maintaining surface integrity.
Our R&D team conducted:
- Tensile testing to assess strength, elongation, and failure behavior
- Bulge testing to analyze multi‑axial deformation
- Advanced simulations to validate tool‑free inflation forming
After successful validation, Speira’s Hamburg site translated the experimental setup into a reliable and scalable manufacturing process - enabling consistent quality beyond prototyping.
Expanding Aluminium’s Creative Potential
The tailored VERSA Form 1050 alloy maintained its surface quality even under extreme stretching, giving the aluminium pillows their smooth and elegant appearance. This project demonstrates what can be achieved when design ambition meets advanced material expertise:
- forming without tools
- no molds or dies
- extreme deformation without compromising surface quality
The collaboration between Speira and TOUMI shows that aluminium offers unexplored creative possibilities and that innovation thrives where engineering and artistic vision come together.
Call or write Get in touch!
Our team is always happy to hear from you. Discuss your next project, ask questions and share your ideas with us – and together we can shape the future as partners. You can reach us by phone and email. We look forward to hearing from you.
Discover more case studies about the use of our aluminium solutions
