How do I calculate the correct crimp diameter and force window?

The Crimp Force Window calculator uses the manufacturer crimp chart target diameter and tolerance, usually plus or minus 0.010 inch, to define the acceptable finished crimp. Enter hose OD, fitting series, and die set to confirm the ferrule compresses into the retention band without over-crimping, which cuts the reinforcement, or under-crimping, which lets the fitting blow off under pressure. Verify with a go/no-go gauge on the first article.

What burst pressure safety factor should a hose assembly meet?

Burst Pressure Margin applies the standard 4:1 ratio, meaning minimum burst must be at least four times the rated working pressure for most hydraulic and industrial hose. Enter working pressure and the hose burst rating to confirm margin after crimping, since a marginal crimp reduces effective burst. For assemblies covered by SAE or EN specs, check the applicable factor, as some low-pressure and thermoplastic hoses use different ratios.

How much hose do I actually consume per assembly after cut loss?

Hose Cut Length Yield adds fitting insertion depth on each end and saw kerf to the exposed length, then Coil/Spool Capacity divides usable coil length by that figure to give assemblies per spool. A 250-foot spool cut into 3-foot assemblies with 2 inches of total insertion and kerf yields fewer pieces than the raw math suggests, and Scrap Hose Value prices the tail-end remnant too short to use.

How many hose assemblies can my leak test station process per shift?

Leak Test Throughput divides available station time by cycle time, which includes fixture load, pressure ramp, the Pressure Decay Test hold, and unload. A 90-second hold with 30 seconds of handling yields about 30 assemblies per hour per station. If decay testing is the bottleneck, compare it against Swage Cycle Time and Operator Utilization to decide whether to add a second bench or parallel fixtures.

How do I price a multi-line route kit?

Route Kit Cost sums Cost Per Hose Assembly for each line in the kit plus fittings, clamps, protective sleeving, Labeling Cost, and Packaging Volume for the shipping container. Because a kit ships as one part number, one missing or wrong-length hose scraps the whole kit, so include a rework and warranty exposure allowance before feeding the total into Quote Price with your target margin.

How do I check minimum bend radius during routing?

Bend Radius Check compares the routed bend against the hose minimum bend radius from its spec sheet, typically listed in inches per hose size. Bending tighter than the minimum kinks the reinforcement and sharply lowers burst pressure and fatigue life. Enter hose type and centerline bend radius to confirm the route is legal, and flag any clamp or bracket location that forces the hose below its rated radius.

Manufacturing calculator category

Hose, Tubing & Fluid Conveyance Products calculators

This category covers the fabrication math for hydraulic hose, industrial tubing, and fluid conveyance assemblies. It is aimed at hose shop planners, crimp operators, and quality engineers who need to hit crimp diameter, prove burst margin, and cost a route kit before it ships. Use these calculators to turn a bill of hose, fittings, and ferrules into a validated, priced assembly.

What this hub covers

Free calculators for hose and tubing fabricators, covering cut length yield, crimp force, burst pressure margin, leak testing, route kit cost, and quote pricing.
Browse hose, tubing & fluid conveyance products calculators for manufacturing planning, quoting, quality, capacity, and operations decisions.

Best calculators in this category

Hose Cut Length Yield: Estimate hose cut length yield as the percent of coil or spool footage that becomes accepted finished cut pieces after trim, scrap cuts, and unusable remnants.
Crimp Force Window: Check crimp force margin for a hose assembly by comparing available crimper force against the required crimp force for the hose and fitting combination.
Burst Pressure Margin: Check burst pressure margin for a hose or tubing assembly by comparing actual or rated burst pressure against the required minimum burst pressure.
Fitting Assembly Time: Estimate total fitting assembly time for a hose or tubing batch from fitting count, assembly rate, and allowance for setup, changeover, and quality checks.
Coil/Spool Capacity: Estimate good hose assemblies or cut pieces producible from a coil or spool, accounting for equipment uptime and first-pass yield.
Leak Test Throughput: Estimate leak test throughput for hose or tubing assemblies from test output, runtime, and test station efficiency.
Scrap Hose Value: Estimate material value of scrapped hose or tubing from scrap quantity, material cost rate, and a recovery or capture factor.
Labeling Cost: Estimate labeling cost for hose or tubing assemblies from label quantity, label cost rate, capture factor, and fixed setup or print run cost.
Assembly Labor Cost: Estimate labor cost for hose or tubing assembly operations from assembly count, loaded labor rate, capture factor, and fixed setup cost.
Cost Per Hose Assembly: Estimate total manufactured cost per hose assembly from material, labor, fitting, and fixed costs to support quoting, margin review, and make-or-buy decisions.
Bend Radius Check: Check whether the installed bend radius of a hose or tubing assembly meets the manufacturer minimum bend radius, and see the margin above the minimum.
Ferrule Inventory Usage: Estimate ferrule or crimp collar quantity needed for a hose assembly production run from assemblies, ferrules per end, and ends per assembly.

Common manufacturing problems solved

hose
tubing
fluid conveyance
crimping
hose assembly
burst pressure
cut length
leak test

Live market signals for this industry

The U.S. has 11,391 plastics and rubber products establishments employing about 815,988 workers (Census County Business Patterns, 2023).

Category questions

How do I calculate the correct crimp diameter and force window? The Crimp Force Window calculator uses the manufacturer crimp chart target diameter and tolerance, usually plus or minus 0.010 inch, to define the acceptable finished crimp. Enter hose OD, fitting series, and die set to confirm the ferrule compresses into the retention band without over-crimping, which cuts the reinforcement, or under-crimping, which lets the fitting blow off under pressure. Verify with a go/no-go gauge on the first article.
What burst pressure safety factor should a hose assembly meet? Burst Pressure Margin applies the standard 4:1 ratio, meaning minimum burst must be at least four times the rated working pressure for most hydraulic and industrial hose. Enter working pressure and the hose burst rating to confirm margin after crimping, since a marginal crimp reduces effective burst. For assemblies covered by SAE or EN specs, check the applicable factor, as some low-pressure and thermoplastic hoses use different ratios.
How much hose do I actually consume per assembly after cut loss? Hose Cut Length Yield adds fitting insertion depth on each end and saw kerf to the exposed length, then Coil/Spool Capacity divides usable coil length by that figure to give assemblies per spool. A 250-foot spool cut into 3-foot assemblies with 2 inches of total insertion and kerf yields fewer pieces than the raw math suggests, and Scrap Hose Value prices the tail-end remnant too short to use.
How many hose assemblies can my leak test station process per shift? Leak Test Throughput divides available station time by cycle time, which includes fixture load, pressure ramp, the Pressure Decay Test hold, and unload. A 90-second hold with 30 seconds of handling yields about 30 assemblies per hour per station. If decay testing is the bottleneck, compare it against Swage Cycle Time and Operator Utilization to decide whether to add a second bench or parallel fixtures.
How do I price a multi-line route kit? Route Kit Cost sums Cost Per Hose Assembly for each line in the kit plus fittings, clamps, protective sleeving, Labeling Cost, and Packaging Volume for the shipping container. Because a kit ships as one part number, one missing or wrong-length hose scraps the whole kit, so include a rework and warranty exposure allowance before feeding the total into Quote Price with your target margin.

Last reviewed 2026-05-12.