Ultra-precision machining in sheet metal processing has emerged as a critical technology in modern manufacturing, catering to industries with stringent requirements for dimensional accuracy, surface finish, and form tolerance. In contrast to traditional sheet metal processing, which may tolerate relatively larger errors, ultra-precision machining aims to achieve tolerances in the micrometer or even nanometer range.

　　One of the key techniques employed is high-precision cutting. Laser cutting with advanced fiber lasers has become a dominant method. These lasers can focus the beam to an extremely small spot size, enabling the cutting of complex and intricate shapes in sheet metal with high precision. For example, in the production of microelectromechanical systems (MEMS) components, fiber laser cutting can create holes and slots with diameters as small as a few micrometers, with minimal heat-affected zones to prevent material deformation. Another cutting technology is waterjet cutting, which uses a high-pressure stream of water mixed with abrasive particles. Ultra-high-pressure waterjet systems, capable of generating pressures up to 600 MPa or more, can cut through thick sheet metal with exceptional precision, leaving a smooth surface finish that often requires little to no post-processing.

　　Precision forming is also crucial in ultra-precision sheet metal machining. Processes such as incremental sheet forming utilize a numerically controlled tool to deform the sheet metal incrementally, layer by layer. This method allows for the creation of complex three-dimensional shapes with high accuracy, as the deformation can be precisely controlled by adjusting the tool path and forming parameters. Additionally, high-precision stamping with advanced die designs and servo presses plays a significant role. Servo presses can control the stamping force and speed with high accuracy, enabling the production of parts with tight tolerances, which are essential for applications in aerospace, medical devices, and high-end electronics.