What is it?

A forming process using water to make shapes from a straight tube or flat sheet of metal. An efficient and repeatable process that can make smooth and difficult forms with high repeatability.

Simple as 123

  1. Start with a straight tube
  2. Bend to an approximation of the final shape
  3. Place in tool, fill with fluid and close tool

Why Hydroforming?

Mass Savings

Tubular structures are inherently more efficient than a stamped assembly since weld flanges are not needed.

Part Consolidation

Replacing multiple stampings with a single modular assembly reduces tool count, assembly stations and improves material handling.

Process Risk

Fewer assembly processes mean less launch risk.
A hydroform’s high dimensional stability means more predictable builds during launch.

Easier builds mean fewer launch issues and simpler troubleshooting.

How Do We Do It?

Standard ERW tubing is brought in from an outside source.  That tube is then bent on a CNC bender into shape.

The bent tube is then placed in the hydroform die where water is injected into the tube as the die is closed.  The tubes final shape and features (including holes) are then captured in the hydroforming phase.

Hydroform Intensive Body Structures

HIBS (Hydroform Intensive Body Structure) was an independent study performed by EDAG, where areas of the car body were compared using traditional stampings and then replaced with hydroform tubes.

To read more about HIBS click here.