Hydroforming | High-pressure internal forming for complex tube geometries
Precise, cost-effective and high-strength components – from prototype to series production
Hydroforming, also known as high-pressure internal forming, is a modern and efficient manufacturing process for producing complex tube and hollow profile geometries. In this process, a tube is placed in a closed die and uniformly shaped to the desired form by means of carefully controlled internal pressure.
This process enables even demanding geometries to be produced with high dimensional accuracy and reproducible quality. Unlike traditional bent or welded constructions, components can often be manufactured in a single forming step, significantly reducing the number of individual parts and joints.
The result is components with a homogeneous material structure, high structural integrity and optimised mechanical properties. At the same time, the process enables efficient use of the available installation space as well as weight reduction whilst maintaining or even increasing strength.
Hydroforming thus offers considerable advantages in terms of functionality, cost-effectiveness and technical performance, both in prototype construction and in series production.
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What is hydroforming?
In hydroforming, a tube is placed into a two-part die and then subjected to high-pressure fluid. The pressure causes the material to conform to the die contour.
- Forming by internal pressure
- Reproduction of complex geometries
- Ideal for confined spaces and interfering contours
- No additional joints
The result is high-precision, reproducible components with complex shapes and high dimensional accuracy.
Advantages of hydroforming | Internal high-pressure forming
The process offers a wide range of technical and economic benefits in both prototype manufacturing and series production:
lower component weight whilst maintaining the same stability
The absence of joints results in high tightness and strength
High design flexibility – complex geometries
High-strength structures – ideal for safety-critical components
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Hydroforming in prototype manufacturing
Hydroforming also offers significant advantages during the development phase:
- rapid realisation of complex component geometries
- realistic validation of designs
- reduction in development times
- direct optimisation of components
- space-optimised piping
Hydroforming in series production
For series production, the process offers high process reliability and cost-effectiveness:
- stable and reproducible manufacturing processes
- consistently high quality
- efficient production of complex components
- reduction in assembly costs