Partner Content
Economy and Efficiency with Tubular Hydroforming

Tubular hydroforming is an economical, flexible and efficient manufacturing process used to shape metal alloys, such as aluminum and steel, into complex shapes by using water pressure. The process is used to produce engine cradles, exhaust systems, frame components, trailer hitch tubes and other components.

“Tubular hydroforming is closer to molding than stamping,” explains Brett McKenzie, Hydroform/FEA Engineer at Schuler North America. “Hydroforming increases design flexibility, strength, durability and consistency in precision and quality. It can consolidate parts that may have been stampings and weldments into one process to produce the required part.”

Schuler North America’s Hydroforming Production Center has a team of engineers with extensive expertise in various materials—including aluminum alloys and dual-phase steels. The hydroform process work-hardens the material and produces a higher strength, finished part compared to the base tube material. One customer, for example, was able to turn nine different parts into one hydroformed tube after collaborating with Schuler’s engineers—an ongoing project that has been around for more than 10 years! 

“We can fit multiple part types—with totally separate geometries and thickness variations—in just one die,” says Chris McMahon, Sales Manager at Schuler North America. “Efficiency, quality, and economy are paramount, especially for OEMs, and our production of over one million parts per year speaks for itself.”

Schuler’s Hydroforming Production Center is a part of the Canton, MI, North American headquarters and offers full turnkey hydroforming solutions—including design, feasibility, tryout support and other inhouse value-added processes such as laser cutting and minor assembly. The facility already houses 3500- and 8500-ton hydroforming presses, with the latter being the largest hydroforming press in the United States. Schuler recently announced the addition of a new 5000-ton hydroforming press, bending cell and automation technology. Read the full press release here.