Many parts in one. Any component that is comprised of a number of separate parts but could possibly perform better if it were one conglomerate part makes a good candidate for HDT tube hydroforming. A good example is a T- or Y-section exhaust component. The welded-joint that connects two tube sections to form the T or Y is usually the culprit for cracking and rusting, reducing the exhaust system’s life span. Tube hydroforming can form this type of component in one die; and the resulting component produces better exhaust flow for improved emissions and harmonics. The component design can be altered as well to widen the mixing area, improving emissions further.

Parts that are difficult to stamp. Conical shapes pose some challenges for stamping operations, but are often used in places where large and small diameter tubing meet. A conical shape is used to join the exhaust piping to the muffler. These cones often require several operations, or the expensive spin-forming process, to properly form the component. With hydroforming, these cones can be formed easily. Often two hydroforming cavities can be included in one die which enables manufacturing of four cones at once.

Complex shapes. If your design space demands that a component contain a series of bends, or other complex shapes, hydroforming could be the right process to produce it. In most instances, hydroforming can produce in one part what might have required two or three otherwise.