Abstract: A hydroformed control arm for a vehicle and a method of making the same is provided. The control arm includes a generally U-shaped member being hydroformed from a continuous, unitary tube. The generally U-shaped member includes varying cross-sectional areas along its length for improved structural integrity. The generally U-shaped member further includes a pair of pivot bores for enabling the control arm to pivot about a pivot axis. The U-shaped member still further including a ball joint cavity disposed near its apex for receiving a ball joint. The hydroformed control arm thereby eliminates the need for a ball joint bushing.

Abstract: A multi-piece hydroforming tool is provided having a tooling die and a hydraulic pressure source. The tooling die includes a plurality of tooling cavities. Each tooling cavity includes a injector manifold in fluid communication with the hydraulic pressure source. The injector manifolds supply pressurized hydraulic fluid to each of the plurality of tooling cavities independently. Thus, multiple pieces may be formed simultaneously and independently, thereby minimizing the need to discard all the hydroformed pieces if one piece become defective.