Why Plan Hydroforming Tooling and Part Production Together?

Design the tool for the equipment that will use it

The part drawing defines the product. The intended equipment determines the conditions in which the tool will run. A die that can produce the required shape is not necessarily suitable for every machine.

Discussing the intended equipment early can reveal compatibility issues before the tool is built. The following production details also matter to tooling development:

The toolmaker needs to know which factory and equipment will be used for production. If these are settled, the discussion can use the actual operating conditions. If not, explain what is still undecided.

A tooling order is different from a parts order

An order for parts involves sample approval, material for production and scheduled deliveries, as well as tooling. These affect what has to be arranged during tool development and trials.

For in-house production, the customer may order the tooling separately. The tool is then developed for that customer's equipment, with trial responsibilities, samples and any support agreed before work starts.

Toolmaking and part production do not have to be awarded to the same supplier. Even when ordered separately, the tooling must suit the intended production equipment and the customer's finished-part requirements.

Plan secondary operations before the tool is made

Parts leaving the hydroforming die may still need trimming or holes before they can be installed. Sample planning therefore includes any work needed after forming.

If the order is for trimmed parts, trimming needs to be included in both the samples and the quote. When the customer will do further processing, the order instead covers formed blanks made to the agreed requirements.

The operations the factory will complete before delivery affect both the tooling and the trials. ShuiYiYuan can provide supporting operations such as laser cutting as agreed for the part.

Use samples to check dimensions and fit as well as shape

Trials produce parts that can be checked for shape, critical dimensions, interfaces and fit with other components.

If the part will be installed in an assembly, the customer may need samples for fit checks or functional tests. Knowing their intended use before sampling helps both parties agree the quantity and how far the samples need to be processed.

When a sample needs improvement, the first question is what is wrong with the part. That determines whether the tooling or the process needs adjusting. The revised samples are checked again before later production follows the agreed drawing and manufacturing conditions.

Consider production stock when choosing trial material

A sample shows how the tube stock used in that trial formed. Switching material for production may give a different result.

Before trials, the material discussion covers grade, tube dimensions and condition, and who supplies the stock. These details also affect later purchasing. If a grade has not yet been chosen, suitable options can be discussed before selecting the trial material.

After sample approval, production batches use the agreed material and tube stock. If either changes, the factory needs to check whether it can still make the required part and run further trials where necessary.

Plan for repeat orders while arranging samples

Samples establish whether the part meets the agreed requirements. Repeat supply also involves batch quantities, order frequency, material supply and delivery dates, all of which affect production planning.

Expected volumes help the factory plan tooling, trials and later production. Demand does not have to be fixed at the sampling stage: the current sample requirement and an estimate of later batches are useful starting points. A forecast is not an order commitment.

After sample approval, actual orders set the production quantities and delivery dates. A revised drawing, material change or added operation may also require tool changes or another sample approval.

What carries forward when one factory handles the work?

When one factory develops the tool, runs trials and produces the parts, it can carry the material choices, manufacturing conditions and part requirements established during trials into production. That includes:

• the part drawing and changes agreed during trials;
• the material, tube stock and equipment used for the samples;
• the results of sample measurements, interface checks and customer fit tests; and
• trimming and other operations to be completed before delivery.

By the time production begins, the factory already knows which sample adjustments were made and what the customer approved. This can reduce repeated discussions. Cost and lead time still need to be established for the particular project.

ShuiYiYuan provides hydroforming tooling development, trial parts and contract manufacturing. You can commission these together or agree individual stages. See our custom tube hydroforming services for the work we offer, and the tube hydroforming cost guide for tooling, sample and production charges.