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American Hydroformers Employs Faro Edge Scan Arm HD

American Hydroformers Employs Faro Edge Scan Arm HD

At American Hydroformers we recently obtained and implemented a new Faro Edge Scan Arm HD that enables enhanced product development, inspection, and quality control. As a 3D scanning and probing device, the Faro Edge Scan Arm HD provides capabilities such as rapid prototyping, reverse engineering, 3D modeling and rapid point cloud collection and comparison. Ideal for scanning challenging materials, the Faro Edge Scan Arm HD also allows for contact and non-contact measurements.

  • Rapid Scanning Speed
  • High Definition Data
  • Up to 2,000 Points per Scan Line
  • Fast Frame Rates
  • Scan Challenging Materials
  • Highly Accurate and Repeatable
  • Contact & Non-Contact Measurements

Acquiring this new Faro Edge Scan Arm HD will allow American Hydroformers to probe virtually any part or tube and collect all of the data needed to reproduce it.  With up to 2,000 actual points per scan line, extreme resolution and high accuracy, we are able to reproduce even the most intricate parts and components. The actual setup of the scanning arm features an extra wide scan stripe as well as fast frame rates. This allows for increased productivity with the large coverage area and the reducing scanning times.

Autoform Hydro Simulation

In addition to the Faro Edge Scan Arm HD, our in-house capabilities also include the utilization of AutoForm Hydro simulation software as well as FEA simulations. Our team of engineers are trained and regularly updated on this software which provides a comprehensive understanding and analysis of the entire hydroforming process. By employing this software in-house and utilizing the simulation process, we supply our customers with rapid verification, shorter development time, and improved process reliability.

  • Easily Identify Forming Issues
  • Rapid Tool Design
  • Accurate Springback Simulation
  • Quality & Cost Improvements
  • Reduced Development Time
  • Improved Reliability
  • Lower Material & Production Costs

By enabling better price controls and reduced tooling expense, American Hydroformers provides a cost-effective source for part production. Unlike other metal forming techniques, hydroforming allows for increased part strength, lower part weight, and greater design flexibility, while also improving overall part quality. Contact American Hydroformers to see how you can reduce your tooling and part costs.

How High-Speed Metal Stamping May Change the Industry

How High-Speed Metal Stamping May Change the Industry

Many aspects about manufacturing remain the same for decades. So many regular processes designed solely to fabricate are rarely altered because change costs money, and so often those in charge don’t levy for deviation because “if it ain’t broke, don’t fix it.”

The evidence of this type of thinking on our industry, however, is usually scant and lacking. In the world of hydroforming, innovation is part of our reality. We have spent many years designing and scheming for the future; we welcome forward-thought and progress.

For instance, take a look at metal stamping and how it has changed. To most untrained people, the process is simply a few lines of work, pushing materials, and stamping forms. It seems simple, though it really isn’t.

A great example of metal stamping innovation comes from a company on the East Coast called Intricate. They have, among other things, perfected the art of high-speed metal stamping.

From this write-up, it proves that with some extra effort and willingness to exceed previous expectations, hydroforming and metal stamping can go very far with a measured amount of success.

Company innovations include manufacturing speeds up to 1,500 strokes per minute, modular and carbide tooling, and multiple-out manufacturing.

With these types of progressions in the metal stamping field, the positives for consumers reaches new heights. By increasing the strokes per minute, Intricate has shown that metal stamping continues to be a viable source of production.

Add to that state-of-the-art machines, and a core group of people who care incredibly about what they do, and you have a recipe for success and a future full of solid enterprise and progression.

For more information on how we can help you, please contact us any time.

5 Benefits of Hydroformed Components

5 Benefits of Hydroformed Components

In the middle of the US, located in what is universally known as the “breadbasket” of America, sits the heart of hydroforming in the Midwest. The sometimes seldom-known but vastly innovative production, which benefits almost every industry big and small, technically termed as “hydroforming,” sits atop ingenuity. Bringing with it vast benefits for just about any industry that chooses to use its simple, yet effective design principles.

Here are 5 benefits of hydroformed components :

1. Simple but strong products. Hydroformed components are designed strong, and built to last a long time. It’s just how they are produced. Hydroformed products often beat out similarly designed products made to perform in the same manner.

2. Increased ductile and tensile strength. Compared to regular products of the same design, hydroformed products exhibit an increased ability to be drawn out (ductile), and used in restrictive, tense environments (tensile). This has to do with the selection of metals used for design, thanks to years of consistent research.

3. Cost-effective savings. Because of the design concept, shaping ductile metals into lightweight components brings with it an incredible savings. Add to that low material costs, and the savings is passed back on.

4. A variety of production methods. With hydroforming, there’s something for everybody in terms of design technique. From tube hydroforming to deep draw hydroforming to metal stamping, any type of component is open to design.

5. Efficient production technique. Unlike traditional means of production, hydroforming offers several time-saving measures, like quick changeover times, reduction in tooling, quicker operations, and less need for manual operators. Meaning components are made faster, and with less wait time.

All in all, hydroforming in the Midwest beats out many other production and design techniques in the same category. For lightweight precision, with consistent guaranteed quality, hydroforming offers numerous benefits over traditional methods of production.

For more information on hydroforming, techniques, designs and innovations, please don’t hesitate to contact us. We can walk you through the process to find out how we can help you with your every need.

How Friction Stir Welding Will Eventually Benefit Every Manufacturing Industry

How Friction Stir Welding Will Eventually Benefit Every Manufacturing Industry

Though friction stir welding is a relatively new technology, it is making waves in just about every industry that chooses to adopt and use it. Most notably, perhaps, is the car industry.

Welding in a car plant has moved at breakneck speed in the last 50 years. As the venerable hand-welder was replaced by robotic arms in the mid-century, soon the automobile production line (perfected by Henry Ford nearly a century ago) will be replaced with the soft hum of friction, as two materials are bonded together with a sturdy and “miraculous” bond.

As an article from Car and Driver says:

FSW is a solid-state weld involving no molten metal. Heat generated by pressure and friction is all that’s needed to ensure a strong metal bond.

Additional benefits of friction stir welding are numerous:

Easily bond dissimilar metals together. Even if one is steel while the other is aluminum.

The time it takes is drastically reduced. For example, the simple process FSW makes out of welding two, different metals, would have taken hours longer with fusion welding.

 It’s a safer process. With fusion welding, there are sparks, molten heat, and a need for protective clothing. Not so with FSW. Because as the die rotates atop the seam with applied, consistent pressure, the heat bonds them without sparks or concern for safety.

A lighter weld that adds no extra mass. Unlike fusion welding, which adds metal filler (e.g. unnecessary weight), FSW adds nothing. Which, if one was to argue it, actually reduces the weight of the finished product.

Friction stir welding will no doubt begin to overtake traditional means of welding in ever manufacturing industry over the next decade, just as it did in the aerospace world. We’re excited to see how this burgeoning new way to bond materials becomes the new standard.

For more information on how we can help you, please contact us anytime.

Next Generation Metal Stamping to Grow Significantly Worldwide Over Next Decade

Next Generation Metal Stamping to Grow Significantly Worldwide Over Next Decade

We here at American Hydroformers are big proponents for the metal stamping industry. What began long ago as a means to bolster the manufacturing process into a single stage operation, has come a long way in all those years.

This is evident thanks to a new report outlining the continued growth of the metal stamping global market. Wherein, the CAGR (compound annual growth rate) will rise to 3.02% over the period 2014-2019.

From an article on the continued growth of metal stamping:

The emergence of next generation metal stamping has gained increased traction in the market. Next generation metal stamping helps form metals without using dies. Designing dies is a costly and time-consuming process. Next generation metal stamping helps save time and costs for companies.

A savings that helps lend to the global manufacturers, and then finally to the consumer. By eliminating the extra steps in the metal stamping process, as well as seeking ways for optimal automation, the metal stamping process has reached some of the greatest (and reduced) operational times possible.

The key manufacturer in this equation is the automotive industry, whose increased need for stamped metal and hydroformed products has increased significantly over the last several years, with parts like fenders, headliners, side and quarter panels, exhausts, brake shoes, valves, and hangers leading the charge.

Further, with more and more industries in need of quality, metal stamped products, and the continued need for innovative and above standard design, the market has a strong potential to expand past the prospective end of 2019.

Global manufacturers who currently use metal stamped and hyrdroformed products are setting a worldwide standard for sought after excellence and quality. Meaning, that as more and more create top-notch quality, others will soon want the same result, a factor that could push the boundaries to even greater heights.

For more information on what we do and how we can help you, please contact us any time.

Hydroforming Aluminum Can Help Reduce Weight Of Components

Hydroforming Aluminum Can Help Reduce Weight Of Components

Hydroforming is a method that shapes metal into strong pieces that are also light, in regards to the weight. There are many different industries that use hydroforming. However, the vehicle industry is probably one of the largest applicators of hydroforming. The method has mostly been popular among the production of cars that are known as the “high-end” cars. One of the materials that is frequently used is aluminium.

Previously, there was a focus on traditional stamping and parts that were welded. Hydroforming has certainly emerged into a practical method of manufacturing because of the need to lower the weight of the different components. There has also been a transition of steel to aluminum. Aluminum is making outstanding progress in the industry. When hydroforming aluminum you will receive an even, nice-looking finish that will not need any extra additions or tooling. You will receive the nice finish because the female die gets replaced by a diaphragm made of rubber.

The fluid in the hydraulic is pumped into a component at a very high pressure, and the aluminum is molded into a shape very evenly. The result will be a distinctive shape that has a thickness in the material. Hydroforming aluminum sheets can be a bit challenging sometimes because all of the shapes will not always be symmetrical and regularly shaped.

Some people may want to try cold-forming, but not every cold-forming method will have the necessities to handle all of the tough demands. Since there are some tough aluminum parts that will need plenty of work to form, hydroforming will be the best answer. The hydroforming methods for the different shaped aluminum parts will not cost as much as other methods, like cold-forming.

We certainly understand how several needs are unique. We also understand how important it is to save time and money when it comes to the process of hydroforming aluminum.

Contact us for more information on the benefits of hydroforming aluminum.