A Visual Guide To Hydroforming Using Same-Day Printed Die Molds

Hydroforming is a metal forming process that uses a die molding, over which sheet metal including steel, stainless steel, copper, aluminum and more to be rapidly shaped using highly pressurized fluid, to create precisely formed shapes.

Creating the die molds is a critical part to the process, and traditionally takes days or weeks to be CNC milled to specifications. 3D printing with the ProJet 3500 and Visijet materials allows for robust die molds to be created within hours, and are usable within the same day of being created with no additional post-processing required.

These 3D printed dies can be used hundreds of times on the hydroforming equipment without loss of detail, and additional, exact die copies can be quickly created on the ProJet 3500 printers without delay.

Image 1. How Hydroforming works

Image 2. The 3D STL file of the die mold

STL data for the 3d printed die mold


Image 3. The 3D printed Die in VisiJet materials from the ProJet 3500 3D printer

3D printed die mold part ready for use

Image 4. The 3D printed die mold and cut metal sheet on the hydroforming equipment

3d printed die and cut sheet metal

Image 6. Watch the video of the hydroforming process



Image 7. The finished, hydroformed part

finished hydroformed part from 3d printed die mold

See more info on the ProJet 3500 Series