FOCUS ON GERMANY
In the combined hydroforming and flow-pressing process, the metal tube and thermoplastic component are heated together and formed simultaneously in temperature-controlled conditions.
In the newly developed process, the metal tube and thermoplastic component( s) are heated together and placed into a temperaturecontrolled tool. During internal-pressure forming of the metal tube, the plastic element is simultaneously pressed into its final shape.
Image: @ Fraunhofer IWU.
Funding
The IGF project 01IF23029N, entitled“ Potential of Passive High- Pressure Sheet Metal Forming for the Production of Bipolar Plates on Conventional Presses at Significantly Increased Production Rates,” is run by the Research Association for Steel Application( Forschungsvereinigung Stahlanwendung e. V.). It was funded by the German Federal Ministry for Economic Affairs and Energy through the German Aerospace Centre( DLR) within the framework of the Industrial Collective Research Funding Programme( IGF), based on a resolution by the German Bundestag.
The project aimed to develop and implement a process combination of internal high-pressure forming and impact extrusion. It is funded by the German Federal Ministry for Economic Affairs and Energy( BMWE), based on a decision by the German Bundestag.
injection-moulded preform and is reshaped during the forming process, rather than being moulded in situ. This eliminates the need for injection-moulding equipment and the complex integration of multiple manufacturing systems,” explained Fraunhofer IWU.
In the newly developed process, the metal tube and thermoplastic component( s) are heated together and placed into a temperaturecontrolled tool. During internal-pressure forming of the metal tube, the plastic element is simultaneously pressed into its final shape.
“ For complex polymer geometries, tool slides can be used to control material flow, while preformed injection-moulded parts can be employed where appropriate. Additional components, such as threaded inserts, can also be integrated. After cooling, the finished parts are removed from the tool. Process control largely follows that of a conventional IHF process. Due to the elevated temperatures of both the tool and the workpiece, gaseous nitrogen is used as the forming medium,” concluded Fraunfofer IWU. n
Fraunhofer IWU headquarters at Chemnitz, Germany.
Technical forum: Tube, profile and hydroforming
Internal high-pressure formed and flow-pressed component with threaded insert and bayonet lock.
Image: @ Fraunhofer IWU.
Both newly developed processes and other innovations in tube manufacturing, downstream processing and hydroforming will be showcased live at Fraunhofer’ s Technical Forum on Tube, Profile and Hydroforming Technologies.
The Technical Forum will be held on 30 September and 1 October 2026 in Chemnitz( Germany).
www. iwu. fraunhofer. de / en. html
62 | ismr. net | ISMR September 2026