Design and Fabrication of a Simple Hydraulic Press for Small Metal Forming Operations in Nnewi Auto Parts Cluster

The Nnewi auto parts manufacturing cluster in Anambra State represents one of the most significant informal industrial ecosystems in sub-Saharan Africa, yet many small workshops rely on improvised or inadequate pressing tools for metal forming operations, resulting in low dimensional accuracy and unsafe working conditions. This study documents the design, fabrication, and performance testing of a 10-tonne manual hydraulic press suited to the scale and budget constraints of small workshops in the Nnewi cluster. The press employs a single-acting hydraulic cylinder actuated by a hand-operated pump, with a welded mild steel frame designed to resist the maximum pressing load with a factor of safety of 2.5. Frame dimensions, cylinder bore size, and pump specifications were determined through hydraulic and structural calculations. The fabricated press was tested using sheet metal blanking, tube crimping, and bearing press-fit assembly operations representative of tasks performed in local workshops. Force accuracy was verified using a calibrated load cell, and dimensional precision of formed parts was assessed using digital Vernier calipers. Results confirmed that the press generated consistent forces within 5 percent of set values and produced parts meeting standard dimensional tolerances. Total fabrication cost was 78,500 naira, substantially below the import cost of comparable commercial presses. The study recommends adoption of the design across the Nnewi cluster to improve product quality and operator safety. Keywords: hydraulic press, metal forming, Nnewi cluster, workshop fabrication, small-scale manufacturing.