Hydroforming Process

Vari-Form’s Patented Piercing Technology

The Vari-Form Hydroforming Process

The Vari-Form Hydroforming Process begins with a thorough understanding of customer needs and requirements. Our experienced team can assist with design utilizing the latest CAD technologies, along with development all necessary tooling.

Component prototyping takes place in our engineering and development facilities, using production-intent methods. To date, Vari-Form has completed over 100 different prototype applications.

Pressure-Sequence Hydroforming

  • Tube blank, three to ten feet long, one to six inches in diameter gets placed in the forming die
  • Tube is filled and pressurized with water
  • As dies close, pressure is gradually increased to shape the tube
  • Corners of the component are formed, retaining a constant wall thickness for exceptional structural integrity
After a tube is placed into the tool, the fluid is pressurized as the press closes.  This reshapes the tube without expansion.
  • Vari-Form’s specialized pressure-sequencing approach forms a part without wall thinning or unwanted tube deformation
  • The result: greater structural integrity and engineering accuracy
  • In-the-die hole punching eliminates post-production operations, saving time and cost, helping to assure final part quality
  • Increases formability by applying hydraulic pressure in stages
  • Corner radius areas are formed by exceeding the yield limit of the tube material in a bending mode, rather than in a tensile mode
  • Tube formation is controlled while the die is closing, tendency for the tube to pinch at the die split line is virtually eliminated
  • Vari-Form provides complete capabilities for our global customers currently producing traditional High-Pressure Hydroformed parts
  • Vari-Form’s pressure-sequence hydroforming has revolutionized global automotive production
  • Produce complex parts from tubes between one and six inches in diameter with a wide range of materials including aluminum and ultra, advanced high-strength steel
  • Pressure-sequence hydroforming is a more efficient and productive alternative to stamping
    closed-section assemblies