Hydroforming is a process that utilises highly pressurised fluid in the formation and shaping of metal components. The benefits are that it offers a fast and accurate method for forming complex shapes, but historically it has been considered an expensive alternative to traditional fabrication methods, which is only suited to higher-volume manufacturing. 

Polar Technology (under its metallic brand, SST Technology) developed the HydroLite® process to address industry needs and overcome traditional drawbacks. HydroLite® isa brand-new, robust means of carrying out hydroforming in vastly reduced lead times and with minimal tooling costs. This not only opened up the possibility of using the process at earlier stages of a product cycle, such as development and prototyping, but also ensures that hydroforming is now a viable, enabling option for low-volume fabrication. 

A summary of the key benefits of the process are as follows:

• Provides greater agility- With typical lead times ranging from 2 to 3 weeks, the HydroLite® process is suitable for fast-make, low-volume products and high-pressure industries. 
• Supports multiple iterations- The low tooling investment also means obsolescence is less of a concern to the designer since new tools can be quickly and cheaply redesigned.
• Engineering support- We offer extensive design and process expertise throughout the process, building in design and manufacture and ensuring that we are offering our customers the most optimised solution for their requirements. 
• Improved consistency and quality- HydroLite® is a semi-automated process, capable of delivering accurate repeatability of complex forms with increased quality control. 
• Cost-effective- Low tooling costs and reduced investment in jigs often makes HydroLite® the most cost-effective option. 
• Repeatable thickness control- Enabled by in-house design simulation, with increased flexibility to accommodate design changes throughout the process.
• Works with variety of materials- Ability to process exotic alloys such as Inconel, titanium and stainless steel, from simple or complex pre-forms.

Polar Technology continue to be market-leaders for hydroforming processes, supplying complex exhaust and pipework systems to multiple customers within the motorsport and automotive industries, with our systems incorporating tapered features which support tuning and back-pressure, non-symmetrical geometries and features that to dampen tortional vibrations. This subsequently enhances engine and system performance, as well as supporting overall packaging. 

As just one element of our multi-faceted fabrication offering, any hydroformed products can be combined and integrated with our laser cutting, welding, machining, additive manufacture and insulating capabilities, meaning we can deliver a fully integrated, turnkey component to our customers. 

To find out more about our wider fabrication capabilities, click here: How we make fabricated structures

Or if you have an enquiry as to how the HydroLite® process can enable your technologies, speak to our team here: Contact Us