Mini Hydrostatic Bulge Testing Setup (For Ultrathin Foils)

This is a mechanical testing setup designed to enable controlled biaxial testing of metallic foils and thin laminates in order to facilitate evaluating material formability and characterizing the biaxial stress/strain response of the material. The setup adapts to most modern universal load frames and converts the machine’s crosshead motion into pressurized fluid that is used to drive material deformation within a bulging setup. Tension testing of metallic foils and thin laminates is not an easy task due to edge effect; this setup enables a more robust way of characterizing these materials for critical applications such as the Battery industry.

General Specifications:

  • Adaptability: Most universal load frames (1kN to 20kN) with modern electronics and an I/O card (INSTRON, ZwickRoell)
  • Force Limit: ~5kN
  • Max Test Speed*: ~5 mm/s
  • Max Foil Thickness: ~50 microns
  • Testing Directions: Compression
  • Mounting:
    • Manual: 5kN


  • Very economical way of enabling controlled biaxial testing, with easy adaptability to commercial load frames and relatively simple operation.
  • Ability to test copper and aluminium foils, as well as polymeric based laminates, with different thicknesses (up to 50microns)
  • Interchangeable die inserts to enable a variety of controlled biaxial strain ratios (from 0.2 to 1.0)
  • Dedicated pressure sensor for obtaining stresses
  • Coupled with mi-Sensor in 3D DIC configuration for obtaining strains and synchronizing them with stresses (based on pressure)

Examples of Tests (for Ultrathin Metallic Foils and Polymeric Laminates):

  • Balanced biaxial bulge tests
  • Formability testing via controlled biaxial bulge tests at different strain ratios
  • Low cycle fatigue testing

Applications (for Ultrathin Metallic Foils and Polymeric Laminates _ for The Battery Industry):

  • Obtaining the effective biaxial stress/strain curves of these materials
  • Characterizing the formability (stretchability) of these materials
  • Evaluating material anisotropy of these materials
  • Calibration of plasticity models for such materials in service applications

Micro HBG Tesing Setup in Use: