High-pressure Forming Service

HEYA METAL | Custom Automotive Exhaust Parts Manufacturer Since 1994

English

Internal High-Pressure Forming Process (Hydroforming)

The internal high-pressure forming process (also known as hydroforming or tube hydroforming) is an advanced plastic forming technology, mainly used to manufacture hollow thin-walled components with complex cross-sectional shapes.

Its core technical principle is as follows

First, a pre-bent tube or pre-welded blank is placed into a closed mold with a target cavity. Then, high-pressure fluid (usually water or oil-based emulsion, with pressure up to several hundred or even thousands of megapascals) is injected into the tube. Under the action of the ultra-high-pressure internal fluid, the tube wall undergoes plastic deformation, expands outward, and fits tightly to the mold cavity. Finally, a complex three-dimensional shape consistent with the mold is formed (such as parts with variable cross-sections, protrusions, depressions, or branches).

Our Capabilities

High Material Utilization and Lightweight

Complex structures are directly formed through a single process, reducing welding and assembly work. The material utilization rate can reach over 90%; by processing thin-walled high-strength steel, weight can be reduced by 20% to 40%.

Capability to Form Complex Geometric Shapes

Capable of manufacturing parts with variable cross-sections, multi-bend axes, local protrusions or depressions, and corrugated shapes.

Improved Mechanical Properties

Pressure compensation prevents local thinning, resulting in a wall thickness variation of ＜10% (compared to up to 30% in traditional stamping); the material undergoes cold work hardening during the forming process, increasing tensile strength by 5% to 15%.

Environmental Friendliness and Cost Efficiency

Eliminates the need for multiple stamping and cutting processes, reducing waste by over 50%; replaces traditional welding/riveting, lowering labor and energy consumption, and cutting overall costs by 10% to 30%.

Application

Automotive Manufacturing

Engine brackets, exhaust pipes, turbocharger pipelines, battery pack housings, A/B pillar reinforcements, etc.

Aerospace

Aircraft fuel pipes, hydraulic system manifolds, combustion chamber cooling channels, etc.

Home Appliances & Household Products

Special-shaped copper/aluminum pipes, stainless steel integrally formed sinks, etc.

Applicable Material

Metals: Steel, aluminum, titanium alloy, etc.

Get in touch with us

Service Process

Customer Requirement Collection

Gather customer requirements, including 2D drawings/3D models or samples, technical parameters, performance requirements, packaging styles, logistics methods, and production capacity needs.

Process Evaluation

Based on customer requirements, the technical team conducts a comprehensive assessment of process specifications, technical difficulties, potential risks, and equipment capabilities, and issues a Feasibility Report and Process Flow.

Quotation Arrangment

The cost accounting department calculates the total cost based on the Feasibility Report and Process Flow, provides the most competitive price, and reaches a satisfactory agreement with the customer.

Process Design

After signing the intent agreement with the customer, hold a development kick-off meeting and establish an APQP team. Conduct process and mold design based on historical defect data and PFMEA analysis, and issue design drawings.

Development & Manufacturing

Manufacture molds, jigs, gauges, and special equipment according to the design drawings; conduct trial production in phases such as T1/T2/T3; and produce qualified samples.

Testing & Inspection

Perform 100% drawing verification and confirmation in accordance with customer drawings and technical performance requirements to ensure product compliance.

Sample Delivery & Verification

Deliver samples (qualified through in-house inspection) to the customer for confirmation and verification, and collect customer feedback.

Mass Production

After verifying product stability through trial production phases including T1/T2/T3/PP/PV/SOP, conduct PFMEA verification, SPC process capability analysis, production capacity verification, MSA analysis, personnel training, and preparation of standardized documents. Enter mass production only after obtaining PPAP approval.

Why Choose Us

Choose us, and we promise to do everything needed to ensure a successful and satisfactory working partnership. The 4 reasons set out below will give you an insight into us.

Advantage 01

Various Production Equipment

We have 4 units of 600T internal high-pressure forming machines, capable of forming internal high-pressure special-shaped tubes from materials with a thickness of 3.0mm.

Advantage 02

Various Testing Equipment

The company owns a full range of testing equipment, including 3D scanners, martensite content testers, thickness gauges, coordinate measuring machines (CMMs), projectors, salt spray test chambers, metallographic microscopes, tensile testing machines, fatigue testing machines, hardness testers, and roughness testers. These equipment can meet the precision testing and verification requirements for materials, products, and molds.

Advantage 03

Professional Design Team

We have a strong technical team and talent reserve, with the independent capability to develop special equipment, molds, jigs, and gauges. It has 5 design and development personnel, 2 mechatronic programming specialists, and 16 mechanical manufacturing technicians. Additionally, the company collaborates with research institutions and universities to study the application of relevant technologies and holds 30 patents for various technologies.

Advantage 04

Quality Assurance System

We have established a quality assurance system framework and obtained the IATF16949 quality management system certification. It also effectively controls environmental and occupational health and safety aspects, and has obtained the ISO14001 (environmental management system) and ISO45001 (occupational health and safety management system) certifications.