Sheet Metal Service:
Bending & Forming
Parts in days anywhere in the USA.
Sheet Metal Bending offers:
- Repeatability
- High Dimensional Tolerances
- Custom Prototypes and End-Use Parts
Quality Matters | AS9100D Certified, ISO 9001:2015, ISO 13485:2016, & ITAR Registered
* Not all locations have all certifications and registrations. Parts requiring these will be made at facilities with the correct certifications and registrations.
Our Digital Manufacturing Process is Simple.
Upload a CAD file and request a quote.
Our team starts production after finalizing project specifications and accepting the quote with you.
When the part has been completed and finished, it passes through quality control.
After your part goes through quality control, our team ships the part(s) to you.
What is Sheet Metal Bending?
Sheet metal bending involves shaping a metal sheet into a desired form or angle by applying force at a specific point, resulting in a permanent bend or curve. Various tools and machines, such as press brakes, rollers, and bending machines, are used in this process. It is commonly used in manufacturing industries to create HVAC ductwork, metal enclosures, and automotive parts. Additionally, the bending angle and degree of curvature can be adjusted based on the desired outcome. Moreover, various materials, including aluminum, stainless steel, and copper, can be used. Accurate measurements and precision are critical in bending sheet metal to ensure consistency and quality in the final product.
How does Sheet Metal Bending work?
Sheet Metal bending is a standard metal forming process that involves manipulating metal sheets using various tools and machines. During the bending process, the sheet metal is often clamped between a punch and die and then pressed to create a bend at a specific angle. Several factors determine the amount of force needed to achieve the desired turn, including the type of metal being used, the thickness of the sheet, and the bend angle.
There are various methods for metal bending, including air bending, bottom bending, coining, roller bending, and V-bending. Each technique offers unique advantages and is selected based on the project’s specifics. After bending, technicians remove the excess material by various machining processes like trimming and cutting. Overall, bending sheet metal is a crucial process that creates durable, high-quality metal products for multiple industries and applications.
Sheet Metal Bending & Forming Advantages
Sheet metal bending and forming has revolutionized how products are designed and manufactured. The following are a few of the advantages of sheet metal bending and forming:
- Strength & Durability - Parts designed well have increased structural integrity.
- Rapid Prototyping - Quick turn around times on prototypes accelerating product development.
- Cost - Less expensive than forging and casting metal.
Sheet Metal Bending & Forming Disadvantages
While there are a lot of advantages to bending and forming, there are also some disadvantages to consider:
- Bad Designs - Can add stresses, distortions, and thinning.
- Labor Intensive - Each bend means more steps to each project.
Sheet Metal Bending Services at Prototek
OEM:
Amada and Birmingham
Lead Time:
1 – 15 Days
Max Dimensions:
Roll Length & Diameter: 4-3/4 in (capacity based on Mild Steel)
Pinch Adjustment: Standard
Material:
Aluminum, Copper, Stainless Steel, Titanium, and several other metals.
Custom Sheet Metal Materials
Prototek Digital Manufacturing offers various sheet metal fabrication capabilities, including bending and forming. Our experienced team works with multiple materials to bring your designs to life, from common steels and aluminum to specialty alloys. We have the equipment and expertise to handle your sheet metal needs, no matter the complexity or material. Contact us today to discuss your project and how we can assist with your sheet metal bending and forming requirements.
Metals
- Aluminum
- Brass
- Bronze
- Copper
- Nickel Based High Temperature Alloys:
- Inconel
- Invar
- Kovar
- Nitronic 60
- Stainless Steel
- Steel
- Titanium
- Tool Steel
Does your project require a material not on our list?
Let us know if your project requires materials that are not on the list! We can accommodate other material requests, but quotes may need more time while we source the material.
Designing Recommendations
Sheet metal bending is a complex process that involves various steps, such as material selection, tooling, and setup. To achieve quality bends, it is necessary to consider several factors, including the material’s strength, elasticity, and thickness, as well as the bend radius, angle, and tolerance required for the final product. These factors can influence the quality of the bend and can cause defects like cracking, buckling or wrinkling. Therefore, it is essential to understand the material properties and choose the right tools and equipment to ensure optimal outcomes.
One of the critical aspects of sheet metal fabrication is the k-factor. The k-factor is a mathematical ratio used to calculate the neutral axis of a bend, which separates the stretched and compressed metal regions during the bending process. The k-factor also determines the amount of sheet metal material displaced during bending. Various factors influence the k-factor, including the type of material, bend radius, thickness, and bending method. Understanding the k-factor is vital in sheet metal fabrication. It can help manufacturers accurately predict the material required for a specific bend angle, thus reducing material waste and improving efficiency.
By considering the k-factor, fabricators can create accurate flat patterns to cut the sheet metal to the correct size before bending. The balanced patterns are also used to calculate the bend allowance, the additional material required to compensate for the sheet metal’s stretching during the bending process. Designers and fabricators can use this information to ensure the final product meets the required specifications and tolerances.
In summary, sheet metal bending is a complex process that requires careful consideration of various factors such as material selection, tooling, and setup. Understanding the k-factor is crucial in sheet metal fabrication. It allows manufacturers to accurately predict the material required for a specific bend angle, reducing material waste and improving efficiency. By considering the k-factor, designers, and fabricators can create accurate flat patterns and ensure that the final product meets the required specifications.
| K-Factors | Soft Metals | Medium Metals | Hard Metals |
|---|---|---|---|
|
Air Bending |
|
|
|
|
0 – Mt |
0.33 |
o.38 |
0.40 |
|
Mt – 3Mt |
0.40 |
0.43 |
0.45 |
|
> 3Mt |
0.50 |
0.50 |
0.50 |
|
Bottoming |
|
|
|
|
0 – Mt |
0.42 |
0.44 |
0.46 |
|
Mt – 3Mt |
0.46 |
0.47 |
0.48 |
|
> 3Mt |
0.50 |
0.50 |
0.50 |
|
Coining |
|
|
|
|
0 – Mt |
0.38 |
0.41 |
0.44 |
|
Mt – 3Mt |
0.44 |
0.46 |
0.47 |
|
> 3Mt |
0.50 |
0.50 |
0.50 |
Mt (material thickness) | > (greater than)
Sheet Metal Fabrication Finishes
Choosing the right finish for sheet metal fabrication projects is crucial for looks and protection. Options include powder coating, painting, anodizing, and plating. Each has benefits and drawbacks, so select depending on the application, metal type, budget, and environment. Partnering with an experienced sheet metal fabrication company will guide the right choice of finish, enhancing appearance and increasing durability.
Prototek's
Other Sheet Metal and Fabrication Capabilities
Why choose Prototek for your sheet metal bending next project?
Prototek is a top sheet metal company that offers high-quality services for your next project. With over 30 years of experience in the industry, we have proven to be a reliable partner for clients across various industries. Our company uses state-of-the-art equipment and technology to ensure precision and accuracy in their sheet metal bending services. We also have a team of experienced and skilled professionals who can provide guidance and support through every step of the process. Our company’s commitment to quality, competitive pricing, and timely delivery makes them an excellent partner for any sheet metal project, from prototyping to production. Ultimately, choosing us means working with a trusted partner who will help you achieve your project’s goals efficiently, effectively, and with the highest level of quality.
