In OEM design, engineers are constantly challenged to balance performance, manufacturability, and cost. One component that plays an outsized role in achieving this balance is the formed metal tube. Far more than a conduit for fluids or gases, formed tubes are engineered solutions that impact assembly efficiency, durability, and system reliability across industries.

Why Formed Metal Tubes Matter in OEM Engineering

From an engineering standpoint, formed metal tubes solve three common challenges:

1. Space Constraints in Tight Geometries – OEM designs often require routing through tight spaces. Formed tubes provide precise bends and radii that eliminate the need for multiple fittings, reducing both space requirements and leak opportunities.
2. Improving System Reliability – Every fitting and joint introduces a potential failure point. By designing tubes with integrated bends, flares, or end-forms, engineers minimize connection points, improving long-term reliability under vibration, pressure, and thermal cycling.
3. Enhancing Assembly Efficiency – Pre-formed tubes reduce installation steps on the production line. Instead of manually bending or aligning straight lengths, technicians can install pre-engineered components that fit correctly the first time.

Material Selection for Formed Tubes: Performance Meets Cost

The choice of material has a direct impact on performance. For example:

• Stainless steel offers high corrosion resistance and is a go-to material for medical and food equipment.
• Carbon steel provides strength and cost-effectiveness for structural or hydraulic applications.
• Aluminum balances strength with lightweight properties in aerospace and EV systems.
• Copper and copper alloys are valued for thermal and electrical conductivity in HVAC and refrigeration.

Understanding not just the operating environment but also forming limitations of each material is critical. Engineers must account for factors like bend radius, wall thinning, and potential for work hardening.

Precision Manufacturing Processes for Formed Metal Tubing

Advances in manufacturing technology have expanded what’s possible with formed tubing:

• Mandrel bending maintains interior diameters in tight radii, critical for fluid flow consistency.
• CNC tube forming offers repeatable precision for high-volume OEM applications.
• End-forming techniques (flares, beads, swages) provide reliable connection interfaces without secondary operations.

Engineers who collaborate early with tube forming specialists can optimize designs for manufacturability, often reducing costs and avoiding late-stage rework.

The Future of Formed Metal Tubes in Emerging Applications

As industries shift toward electrification, automation, and renewable energy, the role of formed tubing will expand. Examples include:

• Battery thermal management systems in EVs requiring complex, corrosion-resistant cooling lines.
• Compact hydraulic circuits in autonomous machinery, where minimizing weight and space is crucial.
• High-purity tubing in medical and semiconductor equipment, where cleanliness and precision are mission-critical.

Engineers who understand the capabilities of formed metal tubing — and design with these processes in mind — will be positioned to create systems that not only meet today’s demands but also anticipate future performance requirements.