It is possible to manufacture a complicated 3D shape from in-situ bonded AFS. In case of the second type, i.e. integral foam moulding, the desired geometry of the foamed part is achieved by designing the mould inside which the foam is cast.
In the case of the third type the three-layer composite precursor is reshaped prior to foaming. Heating of such part yields in a 3D shaped foam part. The three-layer composite AFS panels are also reshaped after foaming by forging. If an AFS is made of heat treatable alloys, the strength is further enhanced by age hardening. In order to join two AFS parts or to join an AFS part with a metallic part several joining technologies are employed, such as laser welding, TIG welding, MIG welding, riveting, etc.