Hydrostatic forming has recently been applied as a special method for manufacturing products with complex surfaces from sheet or tube metal. However, effects of technological parameters as well as geometrical parameters of die on formability and quality have not been thoroughly studied. It can be seen from research on hydrostatic forming for cylindrical products that the formation of curve radius at the bottom of cylindrical die has a heavy dependence on input parameters: blank holder pressure, liquid pressure, relative depth of die and relative thickness of work piece. Furthermore, small value of curve radius at die bottom is supposed to prevent the formability due to the difference in forming mechanism between hydrostatic forming and conventional drawing. Therefore, it is necessary that the extent to which the curve radius at die bottom relies on the parameters above be evaluated. Using orthogonal second order design, relationships between the parameters and curve radius are studied and presented as functions and graphs. From that, values of curve radius can be suitably defined in different forming modes.

Forming complex sheet products using hydrostatic forming technology is currently a focus of the majority of forming processes. However, in order to increase stability during the forming process, it is necessary to identify and analyze the dependency of the forming pressure and the quality of a product on input parameters. For the purpose of modeling the forming pressure, this paper presents empirical research on the product of a cylindrical cup made of various materials, including carbon steel (DC04), copper (CDA260), and stainless steel (SUS 304) with different thicknesses (0.8 mm, 1.0 mm, and 1.2 mm), under a defined range of binder pressures. The regression method is selected to formulate an equation that shows the relationship between the input parameters, including the materials (ultimate strength and yield stress), workpiece thickness, binder pressure and the output parameter, and the formation of fluid pressure. The mathematical equation allows us to determine the extent of the effect of each input on the forming pressure. The experimental results can be used for the easier planning and forecasting of the process and product quality in hydrostatic forming.

In the manufacturing of micro-scale components, geometric dimensional accuracy and product quality are critical factors that directly influence both production costs and efficiency. To meet the growing demands in this field, micro-extrusion technology has been developed and extensively applied, particularly in mass and bulk production. This technology is considered an optimal solution for improving dimensional accuracy, enhancing mechanical properties, increasing production efficiency, and reducing costs compared to traditional methods, while also aligning with the current trends of modern industrial development. This study investigates the influence of temperature and friction on forming force, formability, and product quality during the micro-extrusion process. A combined approach of simulation and experimentation was utilized to form cross-shaped coupling components using pure copper as the material. The results indicate a significant relationship between temperature, friction coefficient, and forming force. Furthermore, 550 °C is identified as the most suitable temperature for hot forming, providing a balance between force reduction and product quality. These insights enhance the predictability and control of the micro-extrusion process and contribute to reducing production defects. Ultimately, the findings support wider implementation of micro-extrusion in the manufacturing of high-accuracy small-scale parts and align with modern trends emphasizing miniaturization, automation, and cost efficiency.