IFI designs, engineers, and supports advanced Hot Isostatic Press (HIP) systems for high-performance manufacturing applications. From new system builds to the upgrade and modernisation of existing equipment, we deliver flexible, engineering-led solutions tailored to demanding industrial requirements.
Our expertise spans the full lifecycle of HIP systems, including design, manufacturing support, installation, and ongoing service. We support applications in powder metallurgy, additive manufacturing, and high-integrity component production.
System Overview
A Hot Isostatic Press (HIP) system comprises several integrated subsystems, each critical to achieving controlled high-pressure, high-temperature processing:
- Pressure Containment System (PCS)
- Furnace system
- High-Pressure Gas Management (HPGM) system
- Cooling system
- Power and control system
These systems work together to deliver precise control of temperature, pressure, and process conditions throughout the HIP cycle, ensuring safe, repeatable, and high-performance operation.
Pressure Containment System (PCS)
IFI’s patented Tie Rod Pressure Containment System (PCS) combines high structural integrity with practical advantages in manufacture, inspection, and lifecycle maintenance.
The modular design enables the vessel to be assembled and disassembled, allowing individual structural components to be separated for on-site non-destructive examination (NDE) and routine inspection. This supports improved maintainability and long-term operational reliability.
The Tie Rod PCS is configured in a vertical orientation and can be adapted for either top or bottom furnace loading, with bottom loading being the preferred option. This eliminates the need for a dedicated installation pit, reducing civil engineering requirements, installation cost, and overall project complexity.
This configuration also enhances operational safety and is particularly well suited to HIP systems using Argon as the process gas.
Closure System
IFI’s HIP systems incorporate a quick-opening breech-lock closure and flange design, enabling vessel opening with only a 1/16th rotation. This significantly reduces cycle turnaround time and improves operational efficiency between HIP cycles.
The system is designed to integrate with materials handling equipment, enabling safe and efficient handling of the closure assembly, furnace, and load components during operation.
Furnace System
IFI provides specialist design, refurbishment, and support services for HIP furnace systems, covering a wide range of temperatures, sizes, and configurations.
Capabilities include:
- Small laboratory HIP furnaces
- Large-scale production furnaces
- Heating element technologies, including Kanthal, molybdenum, and graphite
- Quickcan furnace systems
- Furnace furniture and jigging
- Thermal Barrier Assemblies (TBA)
- Supply of spare parts and refurbishment services for existing HIP furnace systems
IFI has developed a global supply chain for furnace parts and assemblies, enabling reduced lead times and cost-effective solutions for clients worldwide.
For selected HIP system designs, IFI offers options to simplify loading and improve production efficiency by retaining the Thermal Barrier Assembly (TBA) within the HIP vessel during loading and unloading operations. This reduces handling requirements and supports more efficient production cycles.
Cooling System
IFI offers bespoke cooling solutions for Hot Isostatic Press (HIP) systems, tailored to specific vessel designs, furnace configurations, and process requirements.
All cooling systems are designed to be removable, allowing ease of access for routine in-service inspection and maintenance.
Cooling options include:
- Internal closed-loop stainless steel cooling coils (upper and/or lower)
- Internal closed-loop stainless steel cooling curtains
- Internal cooling plates (upper and/or lower)
- External cylinder cooling systems
These configurations enable controlled cooling rates, supporting optimised cycle times and consistent material performance.
Control System
IFI’s HIP systems utilise advanced control systems to deliver precise, repeatable control of temperature, pressure, and process parameters throughout the HIP cycle.
The system architecture provides real-time monitoring and closed-loop control of key subsystems, including furnace operation, high-pressure gas management, and cooling. This ensures stable processing conditions and consistent material performance.
The control platform supports data acquisition, process logging, and integration with plant-level systems, enabling traceability and process optimisation. Operator interfaces are designed for intuitive use, while embedded safety systems ensure safe operation under high-temperature and high-pressure conditions.
Control systems can be tailored to meet specific project requirements, including varying levels of automation and system integration.
High-Pressure Gas Management (HPGM) System
The High Pressure Gas Management (HPGM) system is integral to the operation of Hot Isostatic Press (HIP) systems, providing controlled handling of process gas under high-pressure conditions.
The system is responsible for gas supply, pressurisation, circulation, recovery, venting, and analysis, ensuring stable process conditions and safe system operation throughout the HIP cycle.
IFI delivers complete design and engineering solutions for HPGM systems, tailored to specific vessel designs and process requirements. Our approach incorporates high-integrity components and proven supply chains to ensure reliability, efficiency, and compliance with industrial standards.
High-Pressure Gas Compressor
IFI’s High Pressure Gas Management systems are supported by specialist high-pressure compressor expertise within the wider group, including MPA Pressure Services International.
Large HIP Systems
IFI’s design portfolio includes large Hot Isostatic Press (HIP) systems, with hot zone diameters of up to 1500 mm.
Concept designs and feasibility studies have also been completed for very large HIP systems, with hot zone diameters of up to 4000 mm, addressing the challenges associated with scaling high-pressure vessel technology.
Conventional large HIP vessel design is constrained by the manufacture and handling of thick-section, monolithic forgings. IFI’s segmented vessel approach overcomes these limitations by utilising smaller, more manageable forged rings and cylindrical sections, which are interlocked to form a complete pressure vessel while maintaining full structural integrity.
Applications
IFI’s HIP systems support a wide range of advanced manufacturing applications, including:
- Powder metallurgy (PM HIP) – full densification of encapsulated powders into high-integrity components
- Additive manufacturing (AM HIP) – removal of internal porosity and improvement of fatigue performance
- Casting densification – elimination of porosity and increased component life
These processes are widely used in industries such as aerospace, medical, energy, and high-performance engineering.
Discuss Your HIP Project
If you are developing a new HIP system, upgrading existing equipment, or exploring advanced manufacturing solutions, our UK based engineering team can provide expert support.