Monthly archive for June 2013

Improving the World with Hydroforming

Improving the World with Hydroforming

Hydroforming is a cost-effective way of shaping ductile metals into stiff, strong and lightweight pieces.  Practically all metals that can be cold formed are suitable for hydroforming, and without being limited by geometric complexity, the applications are becoming endless.  Here are a few industries which utilize hydroforming:

Aerospace:  The precision and reliability of hydroformed parts is crucial to ensure success and safety in areas such as turbine construction, array antennas and construction of exterior structures.

Alternative Energies:  Much like in aerospace, the components of alternative energy machines demand a lot in form and function.  Be it solar, wind or waves, the flexibility of hydroforming production allows a wide array of metals to be utilized towards producing advanced components for the energy of the future.

Medical:  Due to not being limited by traditional manufacturing methods, hydroforming finds a good niche in producing intricate parts for medical appliances such as pace-makers and advanced prosthetics.  Being as it is so cost-effective, hydroforming has the ability to make much needed medical procedures more affordable to people who truly need them.

Home Appliances:  Hydroforming makes very asthetically pleasing products; because of the unique manufacturing process, pieces come out smooth and free from dents and blemishes.  In the appliance industry, hydroformed parts are moving into the eye’s view as they gain acceptance and use as handles and more due to these unique qualities.

Automotive:  Faster, lighter, stronger seems to always be on the minds of motor enthusiasts, and hydroformed parts fit into this category perfectly.  One of the most recognized uses for hydroforming, components made for vehicles gain durability from eliminating weak points made by traditional shaping and welding techniques.  From retrofitting late-model cars to creating tech-forward alternative fuel vehicles, you can find an application for hydroforming.

Plumbing:  Because the unique array of shapes able to be produced by hydroforming, not only is it excellent for creating strong and dependable fittings for under the sink, but hydroformed faucets and fixtures are gaining emerging acceptance as well.  Limitless arrangements are possible, giving designers unprecidented freedom to create new and beautiful products.

At American Hydroformers, we offer complete assembly level fabrication of automotive structures, as well as industrial laser cutting and stencil work in addition to our quality hydroformed and tube hydroformed products.  Contact us to see how we can improve your products today!

Automated Hydroforming Process using Robotics

Automated Hydroforming Process using Robotics

American Hydroformers announces the addition of a new automated hydroforming cell to augment current capabilities and production capacity.

Fort Wayne, IN–In an effort to continuously improve the efficiency, speed, capacity, and accuracy of their hydroforming process, American Hydroformers has implemented a new automated hydroforming cell.  With the addition of multiple robotically automated stations, American Hydroformers has not only increased production capabilities but also improved overall part precision.  Click here to watch the video of the 3 robots working in the cell.

The automated hydroforming cell employed by American Hydroformers provides a more efficient production process. By producing hydroformed parts and components faster and more cost effectively, overall part prices and turnaround times are reduced. Additionally, by utilizing a completely automated system, American Hydroformers can also better control material costs by reducing waste and scrap.

Unlike other metal forming techniques, hydroforming allows for more complex shapes, increased part strength, lower part weight, and greater design flexibility, while also improving overall part quality. Additionally, hydroforming offers tighter part tolerances with a reduction in the overall manufacturing steps required.

Founded in 2003, American Hydroformers specializes in the tube hydroforming manufacturing process. Our capabilities include numerous metal forming techniques such as hydroforming, hydraulic press work, metal stamping, and tube forming. In addition to hydroformed components, American Hydroformers offers complete assembly level fabrication of automotive structures, robotic welding, and both industrial laser and plasma cutting.

To learn more about American Hydroformers, visit our website at https://americanhydroformers.com/

If you need a hydroforming provider or wish to learn more about our business, contact us today for more details.

What is Hydroforming and Why Use It?

What is Hydroforming and Why Use It?

When many think about the manufacture of metal parts for cars, bicycles, and such,  they often think of  such processes as solid die stamping,  However, in the late 1940’s and 50’s a new process called hydroforming was developed to form metal parts, especially those with asymmetrical and irregular shapes that are difficult for stamping to form.

What is hydroforming?  Simply put, hydroforming uses a high pressure liquid to force a thin metal sheet or tube into a specialized die mold.  Almost all metals capable of being cold formed can also be hydroformed:  aluminum, brass, steel, stainless steel, and high strength alloys.   There are two types of hydroforming; sheet hydroforming and tube hydroforming.

For sheet hydroforming, a metal blank sheet is placed over the mold.  Then, in one type of sheet hydroforming, the mold is closed by a water filled bladder .Water pressure within the bladder is then increased, forcing the metal into the mold.

For tube hydroforming, a raw tube is placed between two dies.  The ends of the dies are then sealed off and water fills the tube.  The water pressure is increased until the tube takes the form of the mold.

The advantages of this process over traditional stamping are many.  It is ideal for forming complex shapes.  Hydroforming also produces parts that are more lightweight and have a higher stiffness to weight ration than stamped parts. Finally, its costs per unit are lower than stamping.

From hydroforming’s initial use in forming kitchen spouts its use has expanded to other plumbing fixtures, to widespread use in the auto and aircraft industry, to the manufacture of bicycles, and to the forming of the handles of appliances.   Hydroforming has even been used to manufacture the brass tube of the Yamaha saxophone.   It has proven itself to be an increasingly versatile tool.

Contact us if you would like to learn more about hydroforming and how it can meet your needs.