Manufacturing Process
Pressure Sequence Hydroforming
Plants

Add up the benefits: Vari-Form out-performs stamping and conventional hydroforming

In the appropriate application, Pressure-Sequence Hydroforming out-performs traditional stamping and conventional hydroforming in nearly every way: 
  • Extraordinary Design Flexibility. Components can be extremely intricate with numerous bends and access holes. Vari-Form's hole-piercing technology, also globally patented, pierces holes in any size or shape - right in the die - eliminating the need for expensive postproduction processing.
  • Fewer Parts, Less Assembly. Where stamped assemblies may require dozens of parts welded together, a Vari-Form assembly requires far fewer. That means less sub-assembly operations. A lower part count also means less welding which translates into improved structural integrity,
  • Less Weight. Fewer parts mean substantial weight savings. Using the Vari-Form process to manufacture space-frame components for example, can make an enormous impact on a vehicle’s total weight.
  • Lower Tooling Costs. In a stamping process a number of dies and assembly tools are required. With Vari-Form, a part can be formed in a single die. In addition, changing the material gauge doesn't require a new die or revised tooling.
  • Less Post-Processing. Vari-Form also eliminates the expensive lubrication and annealing necessary with conventional hydroforming. The component exits the Vari-Form die clean and ready for post-processing procedures, such as welding and painting. In fact, Vari-Form requires far fewer operations with shorter cycle times than both traditional stamping and conventional hydroforming.  Vari-Form's production cells even take less room on the factory floor.
  • Greater Integrity. In structural integrity and accuracy, Vari-Form components greatly outperform the competition. Where conventional high-pressure hydroforming and stamping often stretch the metal, creating thin weak points in the corners, Vari-Form’s variable pressure flows the metal into corners for greater precision and constant wall thickness.
  • Dedicated Staff. From engineering to sales to manufacturing, Vari-Form's motivated staff is determined to meet or exceed customer needs. Ongoing training programs enhance proficiency and ensure continuous improvement.
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Pressure Sequence Hydroforming
See how Vari-Form's patented technology
out-performs traditional processes.

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The Vari-Form Advantage
View animation that details Vari-Form's unique advantages over high-pressure  hydroforming.

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Substantial savings for manufacturers.
Vari-Form hydroforming provides cost-saving advantages in over a dozen automotive applications. From individual assemblies to integrated space-frame components, it’s the ideal production method to meet today's exacting automotive specifications.