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We specialize in the manufacture of hydroformed metal parts. Amalco combines a full range of secondary operations with proprietary hydroforming capabilities to fabricate difficult to manufacture parts. All operations are 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 manufacturer of hydroformed metal domes, covers, enclosures, and custom-made parts. We offer a vertically-integrated facility, with on-location engineering, designing, and prototyping services. We’ve been making metal parts in the USA for over 110 years, and we’ve earned a reputation for producing complex hydroformed parts other shops won’t even quote.

    We cut the metal to the proper size blanks and prepare them for the Hydroforming process.
    Aluminum, brass, bronze, copper, Hastelloy®, Inconel®, Monel®, mu-metal, nickel, stainless steel, steel, titanium, & specialty metals
    Anodizing, assembling, blanking, CNC machining, dip brazing, forming, iriditing, heat treating, Heliarc® welding, painting (wet & powder), piercing, spinning, spot welding, trimming & swedging.


Hydroforming is a single forming operation performed on a specially prepared metal blank, which shapes the metal around the punch; resulting in a seamless (void-free) part. Our proprietary approach results in a higher quality part and usually eliminates the need to perform X-Ray analysis to confirm void-free fabrication integrity. Once a part has been Hydroformed it can be followed by secondary operations which range from custom fabricating to light assembly to finishing.

Amalco is uniquely equipped to perform a full range of secondary operations including: CNC machining, spinning, welding (Heliarc & Spot) dip-brazing, heat treating (Aluminum), anodizing, iridite & painting (Powder & Wet); all performed on-site. Only one purchase order is needed to complete most processes under one roof and under the control of our comprehensive quality assurance program in our clean and efficient facility.


The first step in hydroforming a metal part is choosing the right material

Our expert engineers will help you determine which alloy will best conform to your specifications. We can also source the material for you or work with metal sheets or rolls you already own. We cut the metal to the proper size blanks and prepare them for the Hydroforming process.

The next step is forming a punch in the shape of the desired part.

The metal blank is then placed onto a ring, located on top of the punch. A hydraulic chamber is then closed over the sheet metal blank and fluid pressure is applied to the top side of the unit. At the same time, the punch is pushed up into the blank and the pressure is increased. As a result, the pressure causes the blank to form and take the shape of the punch.

This process allows us to form complex shapes with detailed external concavities that would be nearly impossible to create with traditional stamping or deep draw methods.

Since hydroformed metal parts are made from a solid piece of sheet metal the resultant part is seamless (no welded seams or corners). Therefore, there is no need, in most cases, for additional pressure testing or x-rays to find voids or cracks in the metal. The hydroforming process is also less expensive than other metal forming processes, such as deep draw; only requiring a punch and blank holder. (No die set required since the pressure chamber takes the place of the die set).

If you are wondering if Amalco can hydroform your part, take a look at our Hydroformed Parts Gallery to get a sense of our capabilities.


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 seamless 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 110 years, and have earned a reputation for deep drawing and hydroforming parts other shops declined to quote.


When you choose Amalco as your manufacturer of hydroformed parts, you get:

Design & Engineering Expertise

Our engineers have made countless hydroforming punches. We know exactly how to prepare each blank & preserve the integrity of the alloy — avoiding cracks and imperfections.

Reliable Customer Service

Our engineers are available to work with you from start to finish, whether you need assistance sourcing materials, finalizing your CAD drawings, or choosing secondary operations.

Value-Added Services

We perform many secondary operations on-site, allowing you to manage your entire project on one purchase order.

Contact Amalco’s engineering support team early in your product development process. We can help you make design decisions and save money on tooling and production costs — all while delivering shorter lead times. Send us your CAD drawings today, and our expert engineers will help you get started.


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Tooling for a hydroformed part is typically less expensive than for a deep drawn part, since only a punch and ring are required. If the part can be hydroformed 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.


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.”


With 110 years and four generations of experience, Amalco offers design and engineering support for customers in need of deep drawn and hydroformed metal 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.