Precision Forming for Better Fit and Function

The right tube end can make all the difference in how a component fits, connects and performs. Hydro Tube offers a wide range of tube forming and end-finishing capabilities to meet your design requirements, from precise end preparation to custom-formed features.

Our experienced team and specialized equipment produce consistent, accurate results across a variety of tube sizes, materials and configurations. Whether your application requires a secure hose connection, a precision-fit joint or a custom-fabricated component, we'll help determine the right process for your part.

Tube Forming and End-Finishing Capabilities

Coping, Squaring and Deburring

Clean, accurately finished tube ends are essential for proper fit-up and reliable connections. Hydro Tube provides precision squaring, coping, chamfering and deburring to prepare tubing for assembly, fittings and branch weldments. Hand deburring is available for complex shapes and hard-to-reach areas.

Beading

Tube beading creates a raised ring around the tube end to help retain hoses and support secure connections. We form beads on tubing from ¼" to 12" in diameter in materials including aluminum, copper, carbon steel, stainless steel and titanium. Automated equipment supports high-volume beading on tubing up to 2" in diameter.

Swaging (Reducing)

Swaging reduces a tube's outside diameter to achieve a precise fit with another tube or component. This process is commonly used for tube-in-tube assemblies, hydraulic and pneumatic tubing, and close-fitting joints prepared for silver brazing or additional machining.

Expanding

Tube expanding increases the diameter of a tube end to accommodate a mating tube or frame component. Hydro Tube offers ram forming for tubing from ½" to 3" in diameter, with wall thicknesses from 1/32" to ¼". Automated, multistep expansion is available for tubing up to 2" in diameter.

Flaring

Flaring forms an angled sealing surface at the tube end for connection to compatible fittings. Hydro Tube offers 37° and 45° flares, as well as double flares for applicable designs. Tubing up to 3" in diameter can be flared, and 90° Par Flanging is available for tubing up to 1½" in diameter.

Notching

Tube notching creates shaped cutouts that allow components to fit together for assembly or welding. Depending on the part design and production requirements, Hydro Tube uses press forming, tube laser cutting or machining to achieve the required notch.

Punching

Punching creates holes, openings and other features in tubing, flattened tube ends and brackets. Single-station, multistation and dedicated punching equipment accommodate a range of part designs and production requirements.

Slotting

Slots provide clearance and flexibility for assembly, adjustment and clamping. Hydro Tube uses machining and punching processes to produce slots in tubing to suit the required fit and function.

Crimping

Crimping mechanically reduces a tube's diameter or joins components by deforming the material to create a secure fit. This process can be used to stake tubes together without welding and to join tubes or solid rods, depending on the application.

Press Forming

Custom tooling allows Hydro Tube to form tube ends and other features into specific shapes. Capabilities include flattening, dimpling, trimming to length and producing custom profiles to meet your component's design requirements./tube-bending

End Closing

Hydro Tube can close tube ends by flattening and welding or by installing plugs that are continuously welded using manual or automatic TIG welding. Dedicated orbital forming equipment is also used for press and rotary end-closing operations.

The Right Process for Your Part

Every component has its own requirements for fit, function and manufacturability. Hydro Tube combines tube forming and end finishing with bending, laser cutting, machining, welding and other fabrication services to help simplify production and deliver components built to your specifications.