Learn about bending

 

Learn about bending and the technology we use at Lasered Components

Learn about bending

Learn about bending and the technology we use at Lasered Components

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How does metal bending work?

How does metal bending work?

We use advanced Trumpf 5130 and 5170 press brakes to shape metal with precision, maintaining strength and integrity. Our technology handles various metals and thicknesses, delivering smooth, accurate angles and curves. With 24/7 automation, we ensure fast turnaround times—even for complex designs—without compromising quality.

Through our specialised metal bending process, we actively shape your chosen material by applying controlled force with our advanced Trumpf 5130 and 5170 press brakes, thereby precisely forming it to meet your design specifications. Consequently, we create smooth, accurate angles and curves, meticulously crafting each piece to your exact requirements.

Furthermore, our cutting-edge Trumpf press brake technology enables us to bend a wide range of metals and thicknesses with exceptional accuracy, whilst we maintain full material strength and structural integrity. Indeed, we prioritise precision bending without ever compromising on quality.

By leveraging our highly automated bending process, we efficiently manage projects 24/7, thus delivering impressively short lead times and achieving high turnover even for the most complex shapes.

Material properties that impact airbending precision and tolerances

With careful control, variations in material thickness remain one of the most common obstacles to achieving precise bending tolerances. Indeed, noticeable differences in thickness can occur both within and between sheets of metal.

Although manufacturers typically specify the gauge of various sheet metals in terms of averages, the actual thickness might actually fall anywhere within a certain range for that category.
Moreover, even a relatively small change in thickness can cause a bend angle to deviate by several degrees. Consequently, this significantly affects the final outcome, particularly when we need to achieve exacting tolerances for your components.

By understanding the physics involved, springback refers to the natural “bounce” of metal after pressure application and subsequent release. Specifically, during bending, the sheet metal becomes squeezed on the inside and stretched on the exterior. Consequently, because the material possesses higher compression strength than tensile strength, it inevitably bounces back towards its original form. Although springback remains difficult to calculate precisely, we must carefully consider it when determining optimal bend parameters.

Plasticity and Tensile strength are different terms for a materials flexibility/rigidity.

Furthermore, the plasticity of the material significantly contributes to overall springback behaviour.

 

Essentially, plasticity measures a material’s capacity to deform without breaking while maintaining its new shape. Therefore, metals with higher plasticity frequently prove more suitable for complex shaping and bending operations. Meanwhile, materials with higher tensile strength and less flexibility typically exhibit more pronounced springback..

Despite these challenges, we effectively manage the complications that springback, variations in material thickness, and grain direction create for angle precision. Importantly, our air bending technique allows our skilled Press brake operators to make necessary corrections throughout the process, thereby ensuring we meet tight tolerances consistently on every component.

Through the crystallization process, as molten metal cools, tiny crystals begin to form and grow outward until they meet the surface of a neighbouring crystal. Consequently, each fully grown crystal becomes what we call a grain, with each grain developing in a specific direction. When a grain grows and encounters a grain of a different orientation, a distinctive grain boundary naturally forms.

Each grain is formed of atoms in a crystalline lattice. When a sheer stress is applied, any dislocations move within a grain, the grain boundaries prevent dislocation motion. Strong materials are those that can slow down or stop the movement of dislocations.

Dislocations in the grain structure allow the material to change shape when bending. Cold rolling increases dislocation density, decreasing the likelihood of the material tearing during bending.

Cold rolling deforms/elongates the grains in the same direction as the rolling process.

Material properties that impact airbending precision and tolerances

With careful control, variations in material thickness remain one of the most common obstacles to achieving precise bending tolerances. Indeed, noticeable differences in thickness can occur both within and between sheets of metal. Although manufacturers typically specify the gauge of various sheet metals in terms of averages, the actual thickness might actually fall anywhere within a certain range for that category.
Moreover, even a relatively small change in thickness can cause a bend angle to deviate by several degrees. Consequently, this significantly affects the final outcome, particularly when we need to achieve exacting tolerances for your components.

By understanding the physics involved, springback refers to the natural “bounce” of metal after pressure application and subsequent release. Specifically, during bending, the sheet metal becomes squeezed on the inside and stretched on the exterior. Consequently, because the material possesses higher compression strength than tensile strength, it inevitably bounces back towards its original form. Although springback remains difficult to calculate precisely, we must carefully consider it when determining optimal bend parameters.

Plasticity and Tensile strength are different terms for a materials flexibility/rigidity.

Furthermore, the plasticity of the material significantly contributes to overall springback behaviour. Essentially, plasticity measures a material’s capacity to deform without breaking while maintaining its new shape. Therefore, metals with higher plasticity frequently prove more suitable for complex shaping and bending operations. Meanwhile, materials with higher tensile strength and less flexibility typically exhibit more pronounced springback..

Despite these challenges, we effectively manage the complications that springback, variations in material thickness, and grain direction create for angle precision. Importantly, our air bending technique allows our skilled Press brake operators to make necessary corrections throughout the process, thereby ensuring we meet tight tolerances consistently on every component.

Through the crystallization process, as molten metal cools, tiny crystals begin to form and grow outward until they meet the surface of a neighbouring crystal. Consequently, each fully grown crystal becomes what we call a grain, with each grain developing in a specific direction. When a grain grows and encounters a grain of a different orientation, a distinctive grain boundary naturally forms.

Each grain is formed of atoms in a crystalline lattice. When a sheer stress is applied, any dislocations move within a grain, the grain boundaries prevent dislocation motion. Strong materials are those that can slow down or stop the movement of dislocations.

Dislocations in the grain structure allow the material to change shape when bending. Cold rolling increases dislocation density, decreasing the likelihood of the material tearing during bending.

Cold rolling deforms/elongates the grains in the same direction as the rolling process.

speed, accuracy, and reliability.

The Benefits of Air Bending/Air Forming

  • Only the top two corners of the Die groove and tip of the Punch contact the workpiece.
  • Bend angle is determined by how deep the Punch descends into the Die NOT by the shape of the tooling used.
  • Sharper angle can be produced by lowering the Punch lower into the Die.
  • The same tooling is capable of producing a large range of different bending angles. A 30° Die can produce any angle between 30° and 180°.
  • This method allows corrections to the be made to the bending angle, accounting for any variation in material thicknesses and elastic Spring-back.
  • Fewer marks/scratches on workpiece due to less contact with tooling.
  • Angle precision ±1°
Precision

Our process ensures precise, consistent angles while conserving energy for many metals.

Cut complex shapes

Our advanced press brakes bend intricate shapes and precise angles faster than traditional methods.

Material thickness

We fold metal from 0.5mm to 12mm and can assess designs for up to 20mm upon request.

Need CAD support on your next bending project?

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speed, accuracy, and reliability.

The Benefits of Air Bending/Air Forming

  • Only the top two corners of the Die groove and tip of the Punch contact the workpiece.

  • Bend angle is determined by how deep the Punch descends into the Die NOT by the shape of the tooling used.

  • Sharper angle can be produced by lowering the Punch lower into the Die.

  • The same tooling is capable of producing a large range of different bending angles. A 30° Die can produce any angle between 30° and 180°.

  • This method allows for adjustments to be made to the bend angle, helping to compensate for variations in material thickness and elastic spring-back.

  • Fewer marks/scratches on workpiece due to less contact with tooling.

  • Angle precision ±1°
Precision

Our process ensures clean, consistent angles. For many metal types, it’s also a highly efficient process, conserving energy while delivering exceptional accuracy.

Cut complex shapes

Our advanced press brake technology allows us to bend intricate shapes and achieve precise angles at similar or faster speeds than traditional bending methods.

Material thickness

We can fold metal between 0.5mm to 12mm. We are always willing to look at designs as we expand our tooling range and capabilities upon request up to 20mm thick.

Need CAD support on your next bending project?

Get fast quotes

We accept DXF, DWG and NC files. Please send information about which material, thickness and quantities you require.

Call our sales team on 01376 327 182