What is Hydroforming?:
Hydroforming is a metal forming process that is a cost effective alternative to stamping and other metal shaping methods.  Hydroforming uses a punch tool and a rubber diaphragm (die) to form the parts.  During the hydroforming process, the punch ascends into the fluid forming female die which wraps the material around the tool — creating a part.

Advantages of Hydroforming

Inexpensive Tooling - Most hydroforming processes only require a male die (or hydroforming punch tool) which resembles the shape of the part.  The rubber diaphragm in the hydroform machine acts as a common female die, thus the tooling costs are approximately 50% less than conventional press dies.

Eliminates Multiple Operations - Compared to conventional drawing methods that may require two or three operations, Hydroforming can form the same part in a single operation.

Flexible in Forming Complex Shapes and Contours - Hydroforming can form irregular shapes that may not be able to be formed using other drawing methods.

Adaptable to a Large Variety of Materials - Almost all sheet metals capable of being cold formed can be hydroformed. Different material thickness as well as different types of materials can be formed for the same part without the need to modify existing tooling.

Quick Tool Change - Due to the simplicity of the tooling; set-ups are quick and easy.

Saves in Finishing Costs - In hydroforming, the "wrapping effect" of the diaphragm virtually eliminates any galling or scratches that conventional tools create; which greatly reduces or eliminates costly finishing operations.

Maintains Tight Tolerances - Hydroforming can hold and maintain tight tolerances without using expensive secondary operations needed in other metal forming methods.

Minimal Material Thin Out - Hydroforming allows the metal to flow, unlike other forming processes that elongate or stretch the material. Consequently, the material thin out is minimal.