Senior Flexonics Engineers and manufactures bespoke Exhaust Gas Recirculation Tubing (EGR tube) for the world’s leading brands of diesel trucks and automobiles.

We understand material characteristics and their inherent benefits because our prototyping facilities have completed and proven hundreds of similar projects & components. Matched with decades of field data and applied experience we can assist you with your next product. Senior Flexonics is also experienced with the design and manufacture of complex systems utilizing special materials when greater design flexibility is required.

Our corrugated thin-wall, flexible Exhaust Gas Recirculation Tubing (EGR tube) provides high-temperature durability and minimizes installation problems.

We are experts in designing EGR bellows to reduce vibration between the EGR cooler and the engine. Using in-house hydroforming techniques, we can form corrugations into the tubes, ensuring sufficient flexibility. We use our internal simulation software to develop our designs and optimise durability characteristics, ensuring the components will exceed dynamic life requirements regarding cyclitic thermal expansion & natural resonance frequencies. All design development activities are completed prior to prototype manufacture, to avoid issues during customer engine dyno testing.

Senior Flexonics have the capability to complete RDLA data acquisition on customer vehicles at their proving grounds and conduct extensive validation testing on our in-house test rigs. Testing can be implemented prior to delivery of parts to our customers, giving high confidence of part quality.

Senior Flexonics’ advanced production facilities are equipped with all necessary manufacturing cells to produce and assemble a complete EGR Tube assembly.

Senior Flexonics have experience with many different EGR tube sealing solutions, such as, welded flanges, quench cups, Vanstone forms, O-rings, V-Band clamps & gaskets – we will create custom fit sealing design to ensure a leak tight connection to your system.

From bulk raw materials through to available clean room packaging in quality-controlled environments we have the comprehensive expertise to deliver your next large production run of OEM parts.