Loughborough University is a top-ten rated university in England for research intensity (REF2014) and an outstanding 66% of the work of Loughborough’s academic staff who were eligible to be submitted to the REF was judged as ‘world-leading’ or ‘internationally excellent’, compared to a national average figure of 43%. In choosing Loughborough for your research, you’ll work alongside academics who are leaders in their field. You will benefit from comprehensive support and guidance from our Doctoral College, including tailored careers advice, to help you succeed in your research and future career. This research focuses on assessment of cold recyclability of sheet metal products using numerical simulation and Finite Element simulation along with experimentation. It is intended to study sheet metal processes to address re-formability of the material and assess the possibility of cold re- manufacturing avoiding the melting process in basic recycling as melting metals requires substantial amount of energy. This research will investigate the possibility of avoiding melting and improve cost, time and energy efficiency of metal recycling. This analysis system works downstream the FEA and acts as a post processing mean that focuses on the re-formability and re-manufactureability of the material. The heart of this system is the series of calculations based on the residual formability technique which is studied and developed in this research.