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May 10, 2019

FluidForming Americas Announces Precision Metal Hydroforming Machine

FluidForming marks the first major advancement in metal forming in the 21st century

HARTSVILLE, TN — FluidForming Americas is pleased to announce the availability of a 3-in-1 precision hydroforming machine, the FormBalancer. Using highly pressurized water as the force to form, FluidForming is the first major advancement in metal forming in more than 60 years. It's also he most sustainable and environmentally-friendly metal forming process available.

FluidForming is the first company ever to offer an unprecedented combination of technologies which can be incorporated in a single machine. The company’s family of hydroforming machines, known as FormBalancers, have the following metal forming capabilities:

  • Deep draw sheet metal forming (available force to form  60,000 psi)
  • Optional bladder-based hydroforming (available force to form 14,000 psi)
  • Fluid cell sheet metal forming (available force to form 2,500 tons)

The FluidForming technology is a modern reinvention of hydroforming that uses water pressures of up to 60,000 psi to flawlessly form metal parts and components for a wide variety of industries including the aerospace, automotive, and consumer appliance sectors. The FluidForming technology and equipment offer unparalleled manufacturing flexibility.

That same technology, infrastructure, and capability can be utilized to offer Sheet, Bladder and Hydraulic forming all within the same machine.  In many cases, legacy tooling can be utilized from Bladder Based machines.

Since the forming fluid — pressurized recycled tap water — comes in direct contact with just one side of the sheet metal surface, there are no tooling marks. Therefore, FluidForming is perfect for use on alloys and pre-painted or pre-finished materials. Trademarks, brands, and logos can all be easily incorporated into the design of each part. Post-production finishing work is minimized with FluidForming technology.

With a 99.996% first pass yield success rate, FluidForming offers quality, accuracy, and repeatability that was previously unheard of. Post-production costs are also minimized or eliminated altogether.

“FluidForming is poised to become the go-to solution for metal forming in the coming years. As the only Six Sigma metal forming process available, the implications of FluidForming on the future of the manufacturing industry are wide-ranging and profound. Ideas that were once deemed too costly, or impossible, to be formed from metal can be produced and perfected in a matter of days. Plus, unlike legacy metal forming methods, FluidForming works seamlessly with additive manufacturing and 3D printing technology,” said President and CEO of FluidForming Americas, Paul Benny.

As the first hydroforming company to fully embrace additive manufacturing and 3D printing, FluidForming Americas is well-positioned for the future. The groundbreaking 4-in-1 machine technology is ideal for rapid prototyping and low- to medium volume production with the ability to mass produce.

The machine’s compact design requires a minimal factory footprint and does not necessitate any special structural. Operators are able to transition between metal forming functions within minutes.

FluidForming enables companies to enjoy shorter time-to-market and lower overall cost-to-market ratios. Because the system enables the transition from CAD to 3D-printed tooling (all FormBalancer machines are compatible with 3D printed, metal sintered, steel, aluminum, and composite tools) it’s possible to move from design to production in days rather than weeks or even months.

With dramatically reduced tooling costs, the elimination of sheet metal fixturing, and minimal tooling and equipment wear, production costs are dramatically reduced. Because the 4-in-1 FormBalancer is a closed hydraulic system that uses recycled water instead of costly hydraulic oil, maintenance costs are also much lower than traditional hydroforming or die stamping.

T.O.C. (Total Cost of Ownership) is significantly reduced particularly when compared to four (4) separate machines.  

R.O.I. (Return on Investment) performance is seen in double digits when compared to other single use legacy technologies.

Plant Footprints are reduced, Cost of Placement is less, Operating Costs are less and NO special structural systems are required

ABOUT FluidForming Americas

Founded in Germany in 2000 and established in the United States 2014, FluidForming Americas services clients including Mercedes-Benz, BMW, Miele, Sub-Zero, and other industry-leading manufacturers. FFA has a well-deserved reputation for innovation and a clear vision for the future. The company’s unique approach to sheet metal forming and rapid prototyping represents the first major advancement in metal forming in 60 years. The FluidForming process and technology have profound implications for manufacturing, manufacturing technologies, product design, and profitability. FluidForming Americas is headquartered 50 miles northeast of Nashville, in Hartsville, Tennessee.

FluidForming Americas: 4-in-1 Precision Metal Hydroforming Machine