Category Archive: Press Systems

How To: Determine the Appropriate Technology for High Force/High Speed Applications

Flexibility, performance, capital and operating costs have always been key factors in today’s expanding manufacturing marketplace. For decades hydraulics and mechanical presses were the only options for high-speed, high-force assembly and forming applications. More recently hydra-pneumatics and servo-based systems have emerged as viable low-cost alternatives. So which technology is best suited for a specific application? The following topics can serve as a guideline towards the correct usage.
Aries Engineering is the only manufacturer Headquartered and Manufactured in North America offering both servo driven and hydra-pneumatic solutions.

Servo-Based Technology – HyperCyl-EMA

Capability: Provides exceptional control over force, speed, and distance characteristics. Requires the use of a full PLC/PC based electrical panel and 230V/460V. Best used for push-to-distance or push-to-force applications, push/pull applications and where Extreme repeatability is essential. Signature analysis, data logging, part history, trending and root cause analysis options are also available for added functionality and tracking.

Reliability: Servo technologies are inherently capable and sizing them appropriately is crucial. Expected lifetime is from 3 Years to 5 Years, configured for any application. Long-Term Reliability coincides with maintenance schedules.

Speed: Up to 16.00 in/sec with an extremely high rate of repeatability. Requires a deceleration setting before Contact and Home to maximize tooling and screw life.

Forces: 1-10 Ton in Ball Screw configurations (BS1 & BS2) with a medium dynamic load rating; 1-25 Tons in the Roller Screw configuration with a high dynamic load rating.

Maintenance: 3/6-month lube schedule & periodic belt tension check dependent on usage and environment.

Cost: Can be higher initial cost than comparable Hydraulics. Energy efficiency and ROI achieved with minimal downtime, low noise pollution, rapid setting changes without involving tooling, ZERO environmental pollution, comparable energy usage to hydraulics without the mess.

Hydra-Pneumatic Cylinders – HyperCyl

Capability: Utilizing 2 pneumatic valves for operation and a FRL greatly reduces start up time. Cylinders are available in 5 design configurations and 11 standard sizes. Best used for; crimping, dimpling, peening, swaging, inserting, clinching, pressing, staking, piercing, punching, marking, bending, and forming. When coupled with the IntelliCyl option, (load cell and LVLT) force distance monitoring is available.

Reliability: (MTBS) Mean time between service interval of approximately 4-5 million cycles because down time is not an option. LIFETIME warranty on all HPI – HPS – HZ – HZS – HPT cylinders, 1-Ton through 200-Ton.

Speed: Fast Approach speeds similar to that of a pneumatic cylinder (6 in/sec – 10 in/sec) and High-Pressure speeds similar to that of hydraulic cylinders (1.0 in/sec – 2.0 in/sec).

Forces: 1-200 tons of output force using 30-100 PSI shop air.

Maintenance: 20 million cycles before seals require replacement. Field serviceable by maintenance techs and 24-hour HyperCyl assistance is available. Periodic maintenance depends on application and environment.

Cost: More expensive than Pneumatic cylinders but offers the same clean, quiet & self-contained operation. Less expensive than hydraulic and mechanical systems for both short & long-term investments.

Additional Products:

HyperView Press – SigPOD
IntelliCyl – load cell & linear transducer
HyperPress-C Frame, H Frame, CGB Frame
Equalizing/ Non-Equalizing Units Pneumatic
Mechanical Rod Locks

Industries Served:

HyperCyl Manufacturing Industries Served – Automotive, DoD, Lawn & Garden, Appliance, HVAC, Food & Beverage Packaging, Destructive Testing, ATV/Off-Road

HyperCyl-EMA Industries Served – Medical Device Manufacturing, Aerospace, Automotive, Food Product Manufacturing, Clean Room Environments, Lab Testing

To learn more about our product solutions and how they can benefit your assembly or forming application, contact us today. To discuss your application requirements with one of our experts, request a quote.

Can HyperCyl meet your application needs?

HyperCyl’s products are designed to enable clean, quiet, and precise operations with minimal maintenance requirements. Our diverse product portfolio supports a wide range of industries and applications.


Aries Engineering/HyperCyl is a Michigan-based company specializing in the fabrication of cylinders, presses, and other products for assembly and forming applications in the industrial automation, manufacturing, commercial, and defense industries. Our versatile products cover virtually all segments of industrial production, from medical and electronic device manufacturing to heavy industrial piercing and forming, including:

  • Automotive (engine/transmission, suspension, body)
  • Medical devices (clean-room)
  • Semiconductors (clean-room)
  • Electronic devices
  • Appliances (washer, dryer, etc.)
  • Munitions (bullet manufacture, warhead seal & contain systems)
  • Office furniture
  • Coining
  • Hemming

Meeting Your Application Needs

Whether you need a simple press, high-precision actuator, or fully customized turnkey system, HyperCyl has the manufacturing expertise and problem-solving skills to provide unique solutions for a range of assembly and forming challenges. Our press systems include C-frame, H-frame, and CBG-frame options, and we also offer HyperPierce units available in both equalizing and non-equalizing designs.

HyperCyl cylinders are clean, quiet, and reliable self-contained power sources with versatile designs capable of accommodating various industrial operation requirements.

In addition to our standard product line, we also accommodate special requests, and can tailor our cylinder and actuator designs around the customer’s specific production requirements with reasonable turnaround times and prices.

Quality You Can Expect

When you choose a HyperCyl for your operation, you can expect:

  • The ability to separately regulate the approach and power strokes, providing enhanced control over the process and eliminating the need for cylinder reconfiguration
  • Increased retract force versus competition, allowing for heavier tooling
  • No stored energy hazards as the cylinders do not use mechanical springs to assist the pistons (competition does use internal springs)
  • Increased value over alternative cylinder options, including multi-stage air cylinders and hydraulic cylinders and power units
  • Limited lifetime warranty

To learn more about our product solutions and how they can benefit your assembly or forming application, contact us today. To discuss your application requirements with one of our experts, request a quote.

The Different Types of Industrial Press Systems

An industrial press — more commonly called a machine press — can perform a broad range of tasks that require the application of pressure to form and shape metal. In addition to forming, industrial presses can accommodate tooling for cutting, assembly, and more. Presses are available in many different sizes and may use various energy sources.

There are three types of standard press system frames:

  • The H-frame press allows for easy material pass-through; front to back &/or left to right.
  • The C-frame press facilitates easy loading/unloading from the front, or from either side.
  • The CGB-frame press features a low-profile design and accommodates bench-top use.

The ideal frame and method of applying force will depend on the application. There are five types of industrial presses commonly used in machine shops.

Manual Press

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The Different Types of Industrial Press Systems

Manual presses are sometimes known as a workshop press or arbor press. A manual press derives its power from a human operator. The manual press’s ram can be moved in a linear motion and generates forces using simple methods like leverage. Affordable and straightforward in design, manual presses are ideal for bench-mounting and performing light-duty tasks, like bending and piercing for very low volume operations. The operator controls the press by moving the ram and applying force using a lever or handle.

Pneumatic Press

A pneumatic press uses compressed air to increase the cylinder’s internal pressure, generating linear motion and force. Pneumatic presses generate a relatively low maximum force dependent on the pressure of the regulated air source and the size of the cylinder bore. Although the maximum force may be low, pneumatic presses minimize operator fatigue with no tactile feedback.

Pneumatic presses are typically cost-effective for minimal to periodic use, providing quick and consistent force throughout the stroke range. Typical processes for pneumatic presses may include punching, bending, extruding, forming, and shearing.

Pneumatic Intensified (Air/Oil) Press

These presses are also called hydra-pneumatic presses, or air over oil presses. They use an air over oil intensifier cylinder for the press’s motion. They are controlled pneumatically, but they have a trapped section of hydraulic oil in the cylinder which gets intensified to provide higher forces (up to 200 tons). Air/Oil presses provide a smooth controlled power stroke to the workpiece. A pressure regulator controls the power stroke force, and a hard stop in the cylinder, part, or tooling controls the power stroke length. Hydra-pneumatic presses typically use significantly less compressed air than standard pneumatic presses, so they are more efficient for production environments.

Hydraulic Assembly Press

Pneumo-Hydraulic CylinderA hydraulic assembly press uses a hydraulic cylinder filled with oil, and a hydraulic power unit powered by an electric motor to move the ram and generate force through the hydraulic cylinder. Hydraulic presses are available in a broad range of sizes and capabilities. In general, the hydraulic cylinders’ bore size and regulated operating pressure determine the machine’s maximum force. The hydraulic press delivers consistent force throughout the stroke range and is adjustable based on a pressure switch or force setting.

Servo-Electric Press

A servo-electric press delivers fuller control with flexibility and consistent force throughout the stroke. The servo-electric press is gaining popularity in recent years as the prices become lower. This industrial press type has several advantages, including a long lifespan, energy efficiency, and simple maintenance without messy oil and power units. It uses plant electricity to generate linear motion through a servo motor or drive unit integrated with a ball screw or roller screw actuator. Servo-electric presses also feature high precision and deliver full tonnage throughout the stroke without producing substantial noise, and have complete controllability at the touch of a button.

Rely on HyperCyl for Your Industrial Press Systems

An industrial press delivers force for cutting, assembling, and forming workpieces. With various industrial press systems to choose from, there is sure to be a press that suits your application. At HyperCyl, we have been delivering high-quality hydra-pneumatic press solutions since our establishment in 1994, and HyperCyl-EMA servo press solutions since 2010. Aries Engineering/HyperCyl is a privately-owned, American company with headquarters in Dundee, Michigan.

HyperCyl has been a member of the NFPA since the year 2000, and a charter member of the Assembly Show. We offer UL, CSA, CE panel certifications for any given system. We also hold seven trademarks and six patents on our cutting edge technology.

To learn more about our services and capabilities, reach out to us, or request a quote.