Finding the Right Metal Forming Press: Machines & Methods

Purchasing a new metal forming machine is a huge investment, and there are a lot of factors to consider. So let's take a closer look at the high-level pros and cons of some of the most common metal forming methods and machines.

Spoiler alert: Skip to the end of the article if precision, repeatability, complexity, and sustainability are among your top requirements.

Please visit our website to download the full Metal Forming Machines and Methods guide, which also contains information about the federal Research and Development (R&D) Tax Credit and how purchasing a new metal forming machine may qualify your company for significant tax credits. (Be sure to consult with your tax professional!)

PRIMARY REQUIREMENT: Speed 

Traditional Mechanical Presses

When speed and quantity are your only considerations, then the choice is simple: You need a conventional, mechanical metal stamping press. These workhorses are not suited for complex part formation and should not be used when accuracy, precision, and repeatability are required

PRIMARY REQUIREMENT: Size and Depth 

Hydraulic Press

For low production runs of deeper parts with moderately complex geometries, a conventional hydraulic press may be a good fit. However, if production speeds, tooling costs, non-conforming part waste, and secondary finishing costs are line items you care about, a hydraulic press may not be the right long-term solution.

PRIMARY REQUIREMENT: Size, Depth & Speed

Mechanical Servo Press

Servo presses are faster than hydraulic presses and can cover a wide range of capacities and capabilities. However, servo motors require frequent maintenance and can be unpredictable. As with hydraulic presses, tooling costs, non-conforming part waste, and secondary finishing costs can add up quickly. These presses also lack the accuracy and repeatability of other metal presses and processes.

PRIMARY REQUIREMENT: Depth

Conventional, bladder-based hydroforming

Hydroforming has been the go-to metal forming process for complex part formation since the 1950s. The process is used to form tubes and deep, complex parts for a variety of industries. Separate machines for tube forming and sheet metal forming are required. Although more precise than die stamping, hydraulic, or servo presses, the bladders and diaphragms used in conventional hydroforming machines can limit part complexity. Low forming pressures can further limit part design, accuracy, and repeatability.

PRIMARY REQUIREMENT: Accuracy, Repeatability, Flexibility, Depth, Complexity, Sustainability

FluidForming FormBalancer

If you’re in an industry that prizes precision and accuracy, then the choice of metal forming presses and processes becomes more nuanced. A few of the industries that typically value precision over speed include:

• Aerospace
• Architectural Design
• Automotive
• Healthcare
• Lighting Technology
• Renewable Energy

Traditionally, manufacturers looking for complexity turned to conventional, bladder-based hydroforming because metal stamping, casting, and spinning couldn’t yield complex parts that were consistently accurate. While hydroforming was once the gold standard for precision, new processes and presses enable an even higher degree of complexity, precision, and repeatability. 

If you’re unable to consistently achieve the results you’re looking for with conventional hydroforming, or your new product simply requires a higher level of precision than conventional hydroforming can accommodate, then FluidForming and the FluidForming FormBalancer presses may offer the sustainable metal forming solution you’re looking for.

FluidForming Americas, Inc. is a member of the Precision Metal Forming Association and is AS9100 Rev D, ISO 9001:2015 certified, and ITAR-registered. For more information, visit ffamericas.com or call 1-800-497-3545.