Sheet Metal Service:
Bending & Forming
Our sheet metal bending and forming services offer the following:
- Repeatability
- High Dimensional Tolerances
- Custom Prototypes and End-Use Parts
- Instant and Engineer-Assisted Quotes
- Certifications: ISO 9001:2015, AS9100D, and ITAR
- Instant and Engineer-Assisted Quotes
- Certifications: ISO 9001:2015, AS9100D, and ITAR
-
Instant and
Engineer-Assisted
Quotes - 100+ Materials
-
40+ Surface
Finishes -
Certifications:
ISO 9001:2015,
AS9100D, and ITAR -
In-House Services: 3D Printing,
CNC Machining, Urethane Casting,
and Sheet Metal Fabrication
Our Process is Simple.
Upload a CAD file and request a quote.
Our team will start production.
Once complete, it passes through quality control.
Lastly, 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 used, the sheet thickness, 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 using various machining processes, such as 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
Lead Time:
1 – 15 Days
Max Dimensions:
Press Brake Tonnage: 90 tons
Maximum Sheet Metal Bend Length: 10 ft
Sheet Thickness: 0.003 in – 0.375 in
General Tolerances:
Tolerances on sheet metal parts will be held to ISO 2768 standards or ±0.020 in (±0.508 mm), unless otherwise specified.
Precision Tolerances:
Prototek can manufacture and inspect to tight sheet metal tolerances, including sub ±0.005 (±0.127 mm) tolerances, as per your drawing specifications and GD&T callouts.
Surface Finish:
The Standard surface finish for sheet metal parts is to remove the tabs and deburr the part.
Tapped Holes:
Prototek can accommodate any standard tapped hole thread size in sheet metal parts.
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 a variety of materials to bring your designs to life, from standard steels and aluminum to specialty alloys. We have the equipment and expertise to handle your sheet metal needs, regardless of their 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 several steps, including 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 affect the quality of the bend and cause defects such as 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 regions of metal 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 it is bent. The balanced patterns 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, including 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, ensuring 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 help you make the right choice of finish, enhancing appearance and increasing durability.
Learn More About Sheet Metal Fabrication
Through our resources, you can discover the complexities of sheet metal fabrication and gain insights into creating top-notch designs specifically tailored for this cutting-edge technology.
Rapid Prototyping: Bridging Ideas and Reality
In today's fast-paced world, rapid prototyping makes turning innovative ideas into products easier than ever. By utilizing advanced technologies like 3D printing and machining, designers...
What Is Kovar and Why Is It Important?
Kovar is a significant nickel-iron alloy widely used in electronics, aerospace, and medical devices. Developed in the 1920s, Kovar possesses unique properties, such as expanding...
Composite Materials: Innovations Shaping the Future
Composite materials are transforming industries with strength, lightweight nature, and design flexibility, particularly in aerospace and renewable energy. Advancements like nanocomposites and 3D printing enhance...
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 its 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 us 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 to the highest quality.
