**Abstract**

Hydroforming, in comparison with sheet stamping, is an efficient and economical manufacturing process for complex-shape aerospace composite parts because it does not require the use of a female die. The hydroforming manufacturing method is expected to greatly increase the formability of composite parts by using a controllable heated and pressurized fluid that acts as a support for the composite sheet throughout the forming process. The design of a hydroforming process and a machine to shape complex aerospace composite parts is proposed in this chapter. The design and analysis of a sheet metal hydroforming machine with composite overwrap are presented to sustainably and efficiently produce not only the aerospace composites but also dual-phase and bake hardened steel parts with complex 3D geometry.

**Keywords:** aerospace composite structures, sustainable manufacturing, hydroforming
