FOCUS ON HYDROFORMING
FLEXIBLE FORMING
Hydroforming is a specialised type of die moulding that utilises highly pressurised fluid to form a range of metals into complex, lightweight, strong and durable parts.
“ Both sheet and tube hydroforming processes allow for the seamless forming of new shapes and parts in common metal alloys without welds.”
Hydroforming is a metal fabricating process that can form complex geometries in tubular-based parts and extended deep draws in sheet metalbased parts. Hydroformed parts allow for parts’ consolidation; the reduced number of sub-components reduces assembly costs and increases the strength and stiffness of the final assembly.
The near-net shape manufacturing method uses a combination of fluid pressure and mechanical forces to transform sheet blanks into functional geometries. The process has several benefits such as the ability to achieve deeper draws, more complicated features / complex components and strong metal surface quality. It is a specialised type of die moulding that utilises highly pressurised fluid to form metal. Structural strength and stiffness can be improved and tooling costs reduced because several components can be consolidated into one hydroformed part.
Hydroforming is, in fact, a quick and efficient metal forming method designed to reduce waste while guaranteeing structurally robust parts and components with minimal need for secondary finishing operations. Hydroforming is suitable for shaping intricate, exceptionally complex or asymmetrical / irregularly shaped components( including both convex and
Examples of applications / sectors for hydroforming
■ Aerospace: Lightweight, highstrength components for aircraft and spacecraft.
■ Automotive: Precision-formed parts that enhance vehicle performance and safety.
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■ Medical Devices: High-quality metal components for medical implants, surgical instruments and diagnostic equipment.
■ HVAC & Energy: Durable and efficient parts for heat exchangers, turbines and energy systems.
■ Consumer Electronics: Casings and enclosures for laptops, smartphones and other devices.
■ Lighting: Custom architectural fixtures and various housings etc.
■ Construction: Architectural components, piping / plumbing systems, roof frames etc.
32 | ismr. net | ISMR March 2026