We specialize in the manufacture of hydroformed metal parts. Amalco combines a full range of secondary operations with propriatary hydroforming capabilities to fabricate difficult to manufacture parts. All operations performed at our vertically-integrated New Jersey facility with no offshore outsourcing — Amalco delivers shorter lead times, higher quality and lower costs!
American Aluminum Company is a leading provider of hydroformed and deep drawn metal cans, covers, enclosures, and custom parts. We've been metal forming in the USA for over 100 years.
American Aluminum offers a vertically-integrated facility, with on-location Engineering, design, prototyping, dip brazing, anodizing, iriditing, CNC machining, heat treating, piercing, blanking, forming, heliarc welding, painting (wet & powder), metal spinning & spot welding.
Hydroforming / Hydroform is a manufacturing process where fluid pressure is applied to a ductile metallic blank to form a desired component shape. This process requires hydroforming tools consisting of a punch made in the shape of the desired part, a ring contoured to fit around the punch, and a pressurized forming chamber sealed by a flexible rubber diaphragm.
The typical process cycle starts by placing the metal blank onto a ring that is located over the lower tool (punch). The chamber is then closed over the blank and fluid pressure is applied to the top side of the sheet metal blank. At the same time the punch is pushed up into the blank. The pressure is sufficient to cause the blank to form and take the shape of the punch.
The terms Hydroforming / Hydroform and Deep Draw or Deep Drawing are many times used interchangeably, with Hydroforming now being the industry "buzz word" for metal forming. Both processes offer their own unique advantages to metal forming .The following are some design considerations (criteria) that are taken into account when determining the process to be used for a specific part.
Tooling for a hydroformed part is typically less expensive than for a deep drawn part, since only a punch and ring are required. Deep Drawing requires a punch, die, and blank holder. If the part is conducive to hydroforming and relatively small quantities are desired, hydroforming provides a cost effective solution to forming the part.
Call us as early in your design stage as possible so we can help you benefit from the cost, performance, and material advantages of hydroforming and deep drawing.
Seamless metal forming such as hydroforming eliminates much of the complexity associated with stamping, welding, and traditional metal fabricating. If seams are welded to prevent leakage, welding requires extra secondary inspections such as pressure testing and X-rays to detect voids and cracks. Where design requirements allow, choose seemless deep drawing and hydroforming over stamping or fabrication.
Check with our Engineering Support as early as possible in your product development, even before designs are finalized. We've been making metal parts in the USA for over 100 years, and have earned a reputation for deep drawing and hydroforming parts other shops declined to quote.
With our MIL-Grade Quality System 
, our commercial customers enjoy the same critical quality control standards that have allowed us to deliver Defense Department contracted product for many years. Amalco employs the latest technologies in its QC inspection processes, and maintains its own QC Manual focused on a goal of "Zero Defects on All Products Produced".
Hydroforming is a single operation performed on a specially prepared metal blank which shapes the metal resulting in a seamless (void-free) part. Our propriatary approach results in higher quality and usually alliviates the need to perform X-Ray analysis to confirm void free fabrication. Hydroforming can be followed by secondary operations which range from custom fabrication to light assemble to finishing.
Amalco is uniquely equipped to perform a full range of secondary operations including: spinning, stamping, and CNC machining all in one facility. Heliarc welding, spot welding, riveting, brazing (dip-brazing), heat treating, anodizing and painting performed on-site as one purchase order under one comprehensive quality assurance program, in our clean and efficient facility. Our integrated process results in shorter lead times and lower costs for most customers.
A deep draw and hydroforming specialist will review your project and recommend the optimal solution. Complete and submit the form below to get started.
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With 100 years and 4 generations of experience, Amalco offers design and engineering support for customers who need to manufacture deep drawn and hydroformed metal products and parts. Our team is ready to help you solve design challenges and answer your hydroforming process and deep drawing process questions. If you are new to metal forming and fabrication, Professor Metal is here help you get started.
