FOCUS ON HYDROFORMING
Image: Shutterstock. com. Image: Gestamp.
Tube hydroforming.
the need for most secondary processes. The parts can be as thin or as thick as the design demands, and it can have complex joints, threads and formations,” commented spinning and hydroforming specialist, Helander HQ + Forming in the U. S.
Tubular hydroforming is used when complex components, such as curved sections, are needed. Examples include truck / car door handles and bicycle frames etc.
Other benefits include greater rigidity and strength of tubing; lower weight; the integration of multiple manufacturing steps; fewer joining operations; high repeatability and the production of complex geometries.
“ The main advantage of hydroforming is that it allows complex shapes with concavities to be formed, which would be difficult or impossible with standard stamping,” commented stamping specialist, Gestamp.
“ Tube hydroforming technology is vital for some key parts of chassis and body-in-white, even more now with so many electric [ vehicles in the market ]. This technology allows us to manufacture lighter parts which have better performance and stiffness, because its application transforms different sections along the length of the tube.”
Automotive hydroforming
According to analyst‘ Research and Markets’, the automotive hydroformed parts market grew from US $ 1.37 billion in 2025 to US $ 1.46 billion in 2026. It is expected to continue growing at a CAGR of 6.82 %, reaching US $ 2.18 billion by 2032.
“ Hydroformed components have transitioned from niche engineering solutions to foundational elements in contemporary vehicle architecture, driven by the relentless pressure to reduce weight, improve structural integrity and streamline manufacturing throughput. This frames hydroforming not simply as a fabrication technique but as a strategic capability that intersects product engineering, materials science and supplychain design. Over recent development cycles, vehicle programmes increasingly adopt hydroforming where complex geometries, integrated functional features and part consolidation yield measurable benefits in assembly simplification and performance consistency,” said the analyst.
“ Looking ahead, hydroforming’ s role intersects with electrification and regulatory trends; its capacity to deliver lightweight structural elements and to integrate safety features presents clear alignment with evolving vehicle architectures. Novel alloys and the increased adoption of high-strength aluminium and advanced steels are enabling designers to push geometrical complexity, while maintaining crashworthiness and stiffness targets. Simultaneously, manufacturing processes have matured: two-sided and multichamber hydroforming set-ups, combined with in-line trimming and sensor-enabled cycle controls, are elevating repeatability and reducing scrap. These technological
Hydroformed parts and profiles. shifts are not isolated; they recalibrate supplier-OEM relationships and redefine cost-to-serve calculations,” it added.
Hydroformed parts offer a strong strength-to-weight ratio, improving a vehicle’ s structural integrity.
“ Using specialised die moulds, a unibody component structure can be generated in this technique, rather than
the pieces being welded together. Vehicle fuel economy is significantly influenced by vehicle weight. Automakers are being forced to develop creative ways to lighten automobiles due to government rules relating to vehicle economy,” explained analyst, Business Research Insights.
In conclusion
Images: American Hydroformers Inc.
Hydroforming technology is well suited to structural items, from small and shallow to large and deep parts in various materials( such as aluminium alloys, stainless steel and titanium). It is used, for example, for engine components including deep-drawn parts, in high-strength, heatresistant materials. It is also employed for the expansion forming of tubes, ducts and other irregularly shaped parts.
Complex, close-tolerance parts can be produced, often in one operation. The process also offers higher productivity levels, as multiple parts can be processed in a single cycle. Faster lead times also result, with quick tool set-up.
The process provides consistent material thickness as well as intricate, non-symmetrical or concave shapes. The precision of the process means that there is significantly reduced need for post-processing finishing, trimming, or, in some cases, additional welding. The high-pressure method allows for the use of thinner, high-strength materials, producing components that are much lighter than traditional welded assemblies without compromising durability. n
34 | ismr. net | ISMR March 2026