Tube bending

Metal tube bending is a precision manufacturing process that involves manipulating cylindrical metal tubes into desired shapes without compromising their structural integrity. 

This technique is commonly employed in industries such as automotive, aerospace, and construction to create components with specific curves, angles, or configurations.

In the industry

Using specialized machinery, the metal tube is carefully bent to meet precise specifications, ensuring optimal functionality and fit within a larger assembly. The process requires expertise to account for factors like material characteristic, bend radius, and wall thickness, resulting in versatile components used in various applications.

Automotive, Bicycle and Aerospace

What we can do:

  • Exhaust Systems: Bent tubes are used in exhaust pipes to bypass around vehicle components.
  • Roll Cages: Tubes are bent to form the structural framework of roll cages for safety.
  • Frame Construction: Tubing is bent to form frames for bicycles.
  • Handlebars: Creating curved handlebars for bikes.
  • Aircraft Frames: Tubing is bent to create frames and support structures in aircraft construction.
  • Hydraulic Systems: Bending is utilized in creating tubing for hydraulic systems in aircraft.

Medical Equipment

  • Support Structures: Tubes are to create support structures for medical equimpment
  • Custom Components: Bending ist employed for manufacturing customized components in the medical field.

Quality Furniture

  • Chair and Table Frames: Forming Frames for various types of furniture like tables, etc.
  • Shelving Units: It helps to create custom shelving units with unique designs.

These applications demonstrate the broad range of uses for the tube bending industries where precision and customization are essential. Contact us today and schedule a first video-conference to learn more about our extensive competencies.

Our mission:

Optimized production

We optimize your processes. Costs are reduced. We are driven by quality and individuality.

Create value

Creating complex solutions for our customers is the most important thing for us – simply our core competence.

We manufacture for you:

EV Battery Housings & Battery Enclosures

Exhaust Systems

Automotive Tubes

Structural parts

Tube bending FAQs

How can I optimize tube bending for minimal defects considering material properties and desired bend geometry?

Optimizing tube bending for minimal defects involves understanding the interplay between material properties and desired bend geometry. Factors like material type, wall thickness, and diameter all influence bendability. Analyzing these alongside the desired bend radius and angle allows for adjustments like preheating the tube or using specific tooling. This careful approach minimizes defects like wrinkling or cracking, ensuring high-quality bends.

What's the most cost-effective tube bending method for my production run, considering factors like volume, material, and complexity?

The most cost-effective tube bending method depends on your specific production run. High volume production with simple bends might favor automated CNC bending. For lower volume or complex bends, manual bending or specialized techniques like mandrel bending might be more economical. Considering setup time, machine costs, and potential for automation alongside material and complexity will help you find the sweet spot for your project.

How can I minimize common errors like wrinkling or springback during tube bending?

Minimizing common bending errors like wrinkling and springback involves a two-pronged approach. First, we select the right tooling like wiper dies to prevent material bunching (wrinkling). Second, we optimize the bending process itself. This might involve adjusting the bend speed or using mandrels for tighter radii. Choosing the right material and potentially preheating it can also help reduce springback, the tendency of the tube to partially straighten after bending.

Which bending tool (dies, mandrels, etc.) is best for a specific job to ensure proper part geometry?

Selecting the best bending tool depends on the specific job and desired outcome. Dies are ideal for standard bends, while mandrels offer support for tighter radii and prevent collapsing. Wiper dies help control material flow and minimize wrinkling. After analyzing the bend geometry, material type, and required precision, we will guide you towards the most suitable tool for achieving proper part shape and quality.

What factors should I consider when choosing a metal tube material for optimal bendability and performance?

When choosing a metal tube material for bending, we consider a balance between bendability and performance needs. Ductile materials like aluminum bend easily but might not offer the strength of steel. Conversely, high-strength steel might require more complex bending techniques. We analyze your application’s required strength, weight restrictions, and formability to select the best material for optimal bending and final product performance.

© Metal Competencies, 2022

REMUS Innovation GmbH
Ruhmannstraße 11
A-8570 Voitsberg