Small Diameter Tube Flaring
Small Tube Flaring
Hypodermic tube flaring is a precision metal-forming process used to create a controlled, conical expansion at the end of thin-walled tubing to facilitate secure, leak-resistant connections in medical devices, laboratory instruments, and fluid-delivery assemblies. Because hypodermic tubing is typically manufactured from stainless steel or specialty alloys with extremely small diameters and tight dimensional tolerances, the flaring operation requires careful attention to material properties, surface integrity, and tooling geometry.
The process generally begins with the preparation of the tube end, ensuring it is cut square, free of burrs, and properly cleaned to prevent particle contamination. A mandrel, die, or flaring pin—engineered to a precise angle and surface finish—is then applied using axial force or controlled radial expansion to form the flare without inducing cracks or undesired thinning.
Maintaining concentricity through the flare is essential, as even minor deviations can compromise downstream sealing performance or affect how the tube mates with fittings, ferrules, or molded components. Throughout the process, operators must minimize mechanical stress, chatter, and tool marks, as the interior bore must remain smooth to support consistent flow characteristics and prevent particle shedding.
Advances in automated flaring systems have improved process consistency by integrating servo-driven tooling, force feedback, and in-line measurement capabilities, reducing operator variability and increasing throughput.
Ultimately, hypodermic tube flaring is a specialized yet essential technique that enables the reliable integration of small diameter tubing into high-performance assemblies where precision, safety, and durability are paramount.
New England Small Tube also offers Buffing and Electropolishing for smooth surface finishing.
Contact us today to discuss how these processes can improve your part performance
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