FluidForming Americas

295 Trousdale Way
Hartsville,  TN  37074-2073

United States
615-374-9500
http://www.ffamericas.com
  • Booth: D46352


 Press Releases

  • Hartsville, TN – FluidForming Americas, a leading innovator of precision hydroforming, will be showcasing the capabilities of the 4-in-1 precision hydroforming machine, the FormBalancer, at FABTECH 2019 on November 11-14 in Chicago. The company will also be exhibiting a FluidFormed precision microchannel heat exchanger.

    Visitors to booth Booth 46352 will discover how FluidForming — a modern reinvention of hydroforming — can increase precision, accuracy, and repeatability within their metal forming process.

    FormBalancers can accommodate exacting tolerances and utilize high forming pressures of 4,000 bar/60,000 psi — well over industry standards. The self-contained machine accommodates tight radii requirements of 0.2mm and forming depths of 0.8m to 3560mm. The machines also feature automatic roll feed capabilities with automatic die trimming.

     

    FormBalancers have the following metal forming capabilities:

     
    • Bladderless sheet metal forming

    • Tube forming

    • Bladder-based hydroforming

    • Hydraulic hydroforming

     

    FluidForming’s FormBalancers are compact machines equipped with intuitive, easy-to-operate controls. Maintenance costs are minimal and compatibility with 3D printed tooling slashes tooling costs and dramatically improves time-to-market. Finite Element Analysis (FEA) minimizes trial and error and maximizes efficiency so ideation to production can happen in days, rather than weeks or even months. Finally, nested tooling capabilities facilitate undercuts, logos, and sharp angles while reducing production time and further minimizing tooling costs.

     

    “We’re excited to bring such an innovative product to FABTECH. FluidForming has the ability and capabilities to disrupt the manufacturing industry by bringing innovative solutions to the world of advanced manufacturing,” said Paul Benny, CEO of FluidForming Americas.

    FluidForming Americas, Inc. is a member of the Precision Metal Forming Association and is AS9100 Rev C, ISO 9001:2015 certified

     

    ABOUT FluidForming Americas

    FluidForming Americas is redefining the hydroforming industry with its unparalleled commitment to precision, quality, and repeatability. FluidForming is a Six Sigma metal forming solution for rapid prototyping and advanced manufacturing. 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. The FluidForming process and technology have profound implications for American manufacturing, manufacturing technologies, advanced manufacturing, rapid prototyping, and product design. FluidForming Americas is headquartered 50 miles northeast of Nashville, in Hartsville, Tennessee. 

     

    Contact:

    Paul Benny, FluidForming Americas, CEO 

    800-496-3545

    info@ffamericas.com

  • FluidForming, a New Innovation in Metal Hydroforming, Enables Rapid Prototyping

    HARTSVILLE, TN — FluidForming embodies the first major advancement in metal forming in more than 60 years. Using highly pressurized and recycled tap water as the force to form, coupled with the seamless integration of 3D printed tooling and onsite FEA analysis, FluidForming Americas offers its clients a new way to think about manufacturing. 

     

    The company’s 4-in-1 hydroforming machine, the FormBalancer, works flawlessly with 3D printed tooling; saving the company’s clients hundreds of thousands of dollars in tooling costs per part and dramatically reducing a product’s time-to-market.

     

    With forming pressures of up to 60,000 psi, FluidForming Americas offers unparalleled manufacturing flexibility, accuracy, and repeatability. Not only does the FluidForming technology marry additive manufacturing with metal forming, but FluidForming is also the only company to offer an unprecedented combination of technologies incorporated into a single machine. The company’s family of hydroforming machines, known as FormBalancers, have the following metal forming capabilities and can be integrated with 3D printed tooling:

     
    • Sheet metal forming

    • Tube forming

    • Bladder-based hydroforming

    • Hydraulic hydroforming

     

    “Complexity is free with 3D printing. Not so with injection molding, machining, casting, and other traditional manufacturing processes, where complex part designs make production costs skyrocket,” said President and CEO of FluidForming Americas, Paul Benny. “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.”

     

    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 requirements. Operators are able to transition between functions within minutes. 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 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.

    FluidForming Americas, Inc. is a member of the Precision Metal Forming Association and is AS9100 Rev C, ISO 9001:2015 certified

     

    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, tube forming, and rapid prototyping represents the first major advancement in metal forming in 60 years. The FluidForming process and technology has profound implications for manufacturing, manufacturing technologies, product design, and profitability. FluidForming Americas is headquartered 50 miles northeast of Nashville, in Hartsville, Tennessee.

    CONTACT

    Paul Benny, CEO, FluidForming Americas

    pbenny@ffamericas.com

    800-497-3545

    295 Trousdale Way

    Hartsville, TN 37074-2073

  • Innovative High-Speed Metal Forming Machine to Form Microchannel Fuel Cells

     

    HARTSVILLE, TN — FluidForming Americas is pleased to announce the development of a custom metal forming machine designed to mass-produce microchannel fuel cells. The customized FormBalancer 25 (FB25) is a high-speed metal forming machine developed at the company’s German headquarters. The new machine joined the FormBalancer family earlier this year.

     

    The FB25 is designed to produce microchannel fuel cells at high production volumes. By definition, a microchannel is a channel with a hydraulic diameter below 1mm. Microchannels are used in fluid control and heat transfer and offer inherently low energy consumption heat transfer storage. They are used in a variety of settings including heating and cooling, consumer appliances and the automotive and aerospace industries.

     

    “There’s no other process on the market that can form fuel cells like this. We’re enabling fuel cell technology to become commercialized and more affordable,” said Paul Benny, President and CEO of FluidForming Americas. “The potential for this technology and for the FB25 to change entire industries is profound.”

     

    The new machine is designed to accommodate exacting tolerances and utilizes FluidForming’s groundbreaking hydroforming technology. The FB25 boasts high forming pressures of 2500 bar/36,000 psi — well over industry standards. The machine features automatic roll feed with automatic die trimming and accommodates tight radii requirements of 0.2mm and forming depths of 0.8mm.

     

    Prior to FluidForming, mass production of microchannel fuel cells was extremely challenging. Legacy metal forming methods such as die casting or bladder-based hydroforming are costly, unpredictable, prone to warping, and lack the repeatability of FluidFormed components. 

     

    “The machine will simultaneously produce two plates with an operating cycle of 20 seconds, meeting an annual part requirement of more than 1,000,000 components. With unprecedented accuracy, repeatability, speed, and forming capabilities, the FluidForming technology allows for the first-ever mass production of microchannel plates,” said Jurgen Pannock, FluidForming’s Chief Technology Officer. “FluidForming is the only Six Sigma metal forming process available and the implications of FluidForming on the future of the manufacturing industry are astounding. Ideas that were once deemed too costly, or impossible — like mass-producing microchannels are a reality with our technology.” 

     

    Microchannel production is scheduled to take place in Asia and will supply both Asian and US markets.

     

    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, tube forming, and rapid prototyping represents the first major advancement in metal forming in 60 years. The FluidForming process and technology has profound implications for manufacturing, manufacturing technologies, product design, and profitability. FluidForming Americas is headquartered 50 miles northeast of Nashville, in Hartsville, Tennessee.

    CONTACT

    Paul Benny, CEO, FluidForming Americas

    pbenny@ffamericas.com

    800-497-3545

    295 Trousdale Way

    Hartsville, TN 37074-2073


 Products

  • Microchannel Heat Exchanger
    FluidForming America’s Microchannel Heat Exchanger was produced with FluidForming technology, which allows for the fine detail and pinpoint accuracy necessary for this application....
     

  • FluidForming America’s Microchannel Heat Exchanger utilizes channels as small as 0.008 inches deep and 0.008 inches wide to maximize heat transfer.  The FluidForming technology used to form these plates allows not only for the smallest channels, but for a much more compact and efficient heat exchanger overall.  Legacy technology such as die stamping or bladder forming would not only require a larger design, but would be less accurate in forming, which would cause the performance of the heat exchanger to be less consistent from product to product.  FluidForming America’s Microchannel Heat Exchanger showcases what we do best – finer details and more accurate, repeatable parts.

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