Hydroformed subframe tubes help reduce vehicle weight by forming the structure as a single piece, which cuts down the number of parts and weld points. Variable cross-section hydroforming allows tube diameter and wall thickness to be optimized where loads are higher, achieving more than 20% weight reduction while maintaining strength and stiffness. As a result, vehicle energy consumption and emissions are reduced, while chassis performance remains unchanged.

After forming, high-strength steel tubes are usually protected with electrophoretic coating. Zinc phosphating is often applied as well, helping the coating bond better to the surface. For applications that require corrosion protection, hot-dip galvanizing can also be used to provide long-lasting durability.

Hydroformed frame components significantly reduce fatigue stress by cutting the number of weld joints by more than 60%, which helps avoid stress concentration at critical points. Shot peening is then applied to strengthen the material surface and improve fatigue resistance. With the extra stiffness gained from hydroforming, the structure handles repeated loads more easily, which helps extend fatigue life by around 25–30% and keeps the frame reliable even when working under heavy loads or on rough terrain.