Hydroforming Vs. Metal Stamping: Which Should You Choose?

Hydroforming and metal stamping are metal shaping processes that are often used to create components for industries such as medicine, construction, automotive, and aerospace. One uses hydraulic pressure, while the other uses traditional mechanical pressure.

Depending on your needs, one may be preferable to the other. As each approach has unique processes and specifications, here’s a rundown of hydroforming vs. metal stamping to help you decide. In addition, you can contact Tallmadge Spinning & Metal for all of your metal manufacturing needs

About Hydroforming

Hydroforming is a metal shaping process that uses hydraulic pressure to achieve desired shapes. Hydraulic fluid (either oil or water) is pushed into a chamber, where it exerts enormous pressure on high-strength rubber to shape ductile metals like copper, aluminum, or stainless steel into the desired form.

The use of hydraulic fluid allows more control and lets the metal be shaped in ways that could not be done with other methods. Hydroforming thus works best for fabricating asymmetrical, intricate, or long and shallow parts typically used in the automotive, lighting, and appliance industries.

There is another reason why hydroforming is popular. Metal shaping is usually a hot working process, but it can cause oxidation of the metal and even change its composition. Overheating can cause the metal to become brittle and weak.

On the other hand, hydroforming is a cold working process that can be performed at room temperature. This allows the metal to strengthen and harden as it is shaped.

Hydroforming also saves on costs as only one tool is employed. Intense liquid pressure also leaves the final product with smoother surfaces and fewer abrasions.

The Hydroforming Process

First, a metal tube or flat sheet is placed over a molding tool inside a hydroforming chamber. The molding tool is either a solid female die or a mandrel

Hydraulic fluid is then forced into the chamber and sealed with a rubber diaphragm. This pressure helps create the intended shape

The hydraulic fluids either press the diaphragm against the mandrel, allowing for deep drawing or drive the metal into the female mold, creating convex or concave shapes.

Once the pressure has been released, the punch is retrieved along with the newly shaped metal.

Advantages of Hydroforming

Reduces Tooling Costs

Only one tool is needed, requiring no mating part, reducing upfront tooling costs.

Lighter End Product

Hydroforming can be done with thinner blank metals, making the finished product lighter.

Less Waste

The base metal material can be pre-cut, which helps reduce waste.

Reduced Spring Back

Hydroforming applies greater force, which reduces the likelihood of spring back.

Better End Product

High-pressure fluid, instead of compression, produces a smoother, more uniform finish that requires almost no additional work afterward.

About Metal Stamping

Metal stamping is a time-tested way of shaping metal quickly using pre-formed dies and compression. Steel, aluminum, and brass are some metals that can be shaped into different types of components via metal stamping.

Metal stamping involves a metal sheet, a press, and a die tool. The press applies pressure onto the metal, forcing it onto the die and following the shape. It requires precision and specialized equipment but can also be automated and requires less labor than other methods.​​

It’s best for the mass production of identical metal components because of the repeatability of its process. Metal stamping is advantageous to numerous industries, from consumer electronics to automotive and agriculture.

The Metal Stamping Process

First, the necessary dies and tools are selected and created based on the project’s requirements. These are secured onto the press after. A blank, flat metal sheet is then inserted between the tool and the press.

The press compresses the metal onto the die, forcing it to take on the required shape. 

Advantages of Metal Stamping

Repeatable

Once created, a die can be used repeatedly to form metal materials into the same shape. 

Consistent Quality

The repeatability of metal stamping leads to reliable, high-quality results

Fast

Metal stamping requires fewer movements, allowing for high-speed production and faster time to market

Request a Metal Stamping Quote

We can handle long-run, high-volume production as well as prototypes. Interested in speaking with us about a project idea or pricing? Contact Tallmadge Spinning & Metal for more information or to request a quote.