Hydroforming / Bauhaus Universität Weimar / 2003
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Hydroforming is a technology for shaping/deforming metal tubes. A tube is placed into a two- or multi-part tool defining the desired shape. The openings of the tube are then closed off and a mixture of oil and water is inserted with high pressure, causing the deformation of the metal which fits itself to the outline of the tool. What is special about this technique is that a metal tube can be “inflated” to fit any geometry imaginable – something that used to be possible only for plastics. Hydroforming has become well-known in the automotive industry where it is employed in the production of exhaust manifolds or in the fabrication of sanitary objects like water taps. In spite of its huge potential, however, hydroforming is little known in other fields of product development and design.
Hyfroforming is the key technology in this project for the development of new type of handrail system for public spaces. The idea is to provide a set of building blocks for railings. For a large part, standard components are being used. The hydroformed components are only used for intersections such as curves, changes of direction, branchings etc. This approach also implies a huge advantage for the installation process. The standard tubes do not have to be cut and welded on location but, by means of the integrated hydroformed arrests, can simply be clipped together.
In addition, the product design students developed connection pieces with different integrated functionalities. There is, for example, a lighting source integrated into the handrail that makes possible the precise lighting of the path, staircase etc. where the rail is placed. It is controlled by a motion sensor and therefore only emits light when needed. This type of lighting source could help to reduce the number of parts, wires, foundations etc. needed in public projects as well as help save energy. Another example is a loudspeaker integrated into the rail which is design for use in situations like bus stops or train stations. The use of hydroforming in this project permitted the development of a language of forms which is highly unusual for a handrail system.