Meeting the demands of battery-storage and energy-system suppliers
As companies across the renewable energy landscape — from battery-storage system makers and renewable-energy integrators to heavy manufacturing operations—race to deliver next-gen energy products, they need precision, flexibility, and speed.
That’s where FluidForming Americas comes in. We offer state-of-the-art sheet metal hydroforming, product development, and rapid prototyping services that help energy firms transform complex ideas into robust, production-ready components.
By leveraging our patented metal-forming presses — capable of pressures up to 4,000 bar (60,000 psi) — FluidForming enables shapes and part geometries that might otherwise be too difficult, costly, or impossible with traditional stamping or welding methods. Learn more about the benefits of FluidForming here.
From Battery Storage to Solar Panel Manufactures We Serve the Energy Industry
Companies focused on energy storage and infrastructure—like those working on battery energy storage systems (BESS), electric-grid support gear, or industrial energy systems — often require parts that combine high structural integrity, precise tolerances, and long-term durability.
FluidForming’s technology is a natural fit for this space: our high-pressure, bladder-free hydroforming process yields scratch-free, blemish-free, uniform metal parts — even from pre-finished or patterned metal stock.
That means energy-storage enclosures, heat exchangers, battery housing panels, or structural frames can be formed with the precision needed for reliability, safety, appearance, and repeatability — all without the deformities or surface flaws common to stamping or welded/assembled shells.
Moreover, for applications where heat, vibration, or cyclic loading is expected (common in storage systems, power electronics, solar inverters, and industrial power gear), the structural uniformity and integrity enabled by the careful pre-production finite element analysis work of the FluidForming engineering team minimizes weak spots and stress-concentration zones that can lead to fatigue or failure over time.
Accelerating innovation and prototyping for renewable/solar & energy-infrastructure firms
As the energy sector innovates rapidly — new battery enclosures and forms, refined enclosures, — being able to prototype quickly is essential. FluidForming Americas excels at rapid prototyping and low- to medium-volume production runs, allowing firms to go from CAD design to physical parts in days rather than weeks or months.
For example, clients can iterate on the design of BESS enclosures, solar-storage housings, modular battery racks, heat-exchanger shells, or industrial power equipment housings — evaluating fit, finish, structural integrity, and manufacturability before committing to high-volume tooling. This reduces risk, speeds up development cycles, and shortens time-to-market for energy innovations.
Because FluidForming supports 3D-printed tooling (as well as metal or composite tooling), companies benefit from dramatically reduced tooling costs — the process can cut tooling costs by up to 90% compared with traditional progressive stamping dies.
This makes it economically viable for energy businesses to test multiple design variants or adapt quickly as requirements change (e.g., for different battery chemistries, cooling strategies, or form-factor constraints).
Helping Energy Firms Cut Costs — While Improving Quality & Sustainability
Many energy companies are under pressure to not only deliver high performance but also keep manufacturing costs low and minimize environmental impact. FluidForming addresses both. Because our process uses a single die (rather than multiple progressive dies) and replaces complex tooling setups and secondary operations, it reduces not only scrap and waste, but also labor and tooling overhead.
Additionally, because FluidForming uses water as the forming medium — rather than expensive, hazardous hydraulic fluids — maintenance costs are low and the process is more environmentally friendly than conventional metal forming or hydroforming.
For energy companies aiming to uphold sustainability commitments or meet stricter environmental standards, that’s a clear win. For firms investing in clean energy, storage, or grid-resilient infrastructure, FluidForming’s lean and efficient manufacturing method helps align production practices with overall mission goals — supporting not just product performance, but also corporate sustainability.
Real-World Use Cases: From Heat Exchangers to Battery Enclosures:
- FluidForming Americas has showcased the forming of micro-channel heat-exchanger prototypes: using 28-gauge nickel-plated steel, the FormBalancer achieved extremely fine channels (e.g., 1.7 mm wide × 0.2 mm deep) under high pressure (30,000 psi), producing a compact, high-efficiency heat exchanger ready for testing. Our methods can easily be adapted to thermal management systems in batteries, inverters, or power electronics — where compact, efficient heat exchangers are critical to performance and longevity.
- Our process can handle aluminum, stainless steel, and superalloys (even pre-finished or textured materials); that means rugged yet attractive housings can be produced — with fewer fasteners, welds, or seams, and with superior resistance to corrosion and fatigue. Perfect for battery storage enclosures or structural components.
- For smaller-scale production runs or custom energy products (e.g., bespoke battery racks, pilot systems, niche industrial power gear), FluidForming’s low-volume and rapid-turnaround capabilities offer unmatched flexibility compared with traditional die stamping or welded fabrication.
Why FluidForming Americas Is a Trusted Partner for Energy Innovators
At its core, FluidForming Americas brings together technical innovation, manufacturing discipline, and a commitment to supporting product developers from concept to final part. Some of the advantages that make them especially suited for the energy sector include:
- Very high precision and repeatability: with a 99.996% first-pass yield rate, FluidForming ensures that parts conform reliably to design specs and functional requirements.
- Cost-effective tooling and manufacturing: single-die, nested tooling, compatibility with 3D–printed tools — all helping keep costs low while allowing flexible production.
- Fast prototyping and short lead times: from CAD to physical prototype in days — enabling iterative design, quick validation, and rapid deployment of new products or systems.
- Complex shapes and advanced geometries: ideal for parts with curves, undulations, undercuts, logos, or intricate internal geometries — shapes that may be critical in battery enclosures, heat exchangers, structural frames, or energy-system housings.
- Sustainability and efficiency: reduced scrap, fewer secondary operations, lower maintenance costs, and environmentally friendlier processes — aligning with energy companies’ commitment to sustainability.
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A Bridge Between Energy Innovation and Manufacturable Reality
The energy sector is undergoing rapid transformation — with battery storage, distributed power, renewable integration, and grid-resilience infrastructure all scaling at pace. But having a brilliant design on paper is only half the battle. To make those designs real — safe, reliable, manufacturable, cost-effective, and scalable — often requires breakthroughs in fabrication technology.
That’s exactly where FluidForming Americas delivers value. By offering a modern, high-pressure, hydroforming process built for complex parts and rapid turnaround, they provide energy innovators a bridge: from concept to prototype to production, without the traditional limitations of stamping, welding, or assembly.
Whether you’re working on a next-gen BESS enclosure, a compact and efficient heat-exchanger for thermal management, a rugged structural frame, or a custom energy-system housing — FluidForming Americas gives you the tools (and the expertise) to build it right.
If your team is developing a new energy product and needs high-precision sheet metal parts — or you’re exploring alternative manufacturing methods to optimize cost, speed, and quality — FluidForming Americas is ready to help.
Contact us today to learn more about our precision forming solutions for the energy sector. Or, give us a call at 1-800-407-3545.
FluidForming Americas, Inc. is a member of the Precision Metal Forming Association and is AS9100 Rev D, ISO 9001:2015 certified. ITAR registered.