Custom and Complex Sheet Metal Bending Parts

Sheet metal bending is one of the most critical and technically demanding aspects of metal fabrication. The ability to convert flat patterns into precise three-dimensional forms distinguishes basic metal shops from true precision manufacturers. This comprehensive guide explores the world of sheet metal bent parts, addresses the challenges of complex sheet metal bending, and explains the benefits of customized sheet metal bending services for your specific application.

Bending is a fundamental process in sheet metal fabrication. It involves applying force between two tools, using a press brake, to deform a metal workpiece into the desired shape. This process uses an upper tool (called a punch) and a lower tool (called a V-die).

Bending not only improves the structural integrity of a part but also redistributes stress by increasing its rigidity. This technique helps achieve the specific shapes required for certain applications. For example, creating a curved profile can improve a part's ability to withstand certain types of loads, thereby enhancing its performance and durability.

Sheet metal parts are typically fabricated from a single sheet of metal and therefore should have uniform wall thickness. Generally, materials with thicknesses ranging from 0.9mm to 20mm can be fabricated from sheet (<3mm) or plate (≥3mm), but the specific tolerance depends primarily on the part's design requirements.

The minimum bend radius should be at least equal to the sheet thickness to avoid breakage or deformation of the metal part. Maintaining the bend in the same plane and direction saves time and cost by preventing part repositioning. Furthermore, maintaining a consistent bend radius makes the part more cost-effective.

When bending sheet metal, the inner surface of the bend along the neutral axis will shift. The "k-factor," the ratio of the neutral axis position (t) to the material thickness (t), is used to calculate the bend allowance. Using a k-factor chart can help you calculate the amount of material required to ensure bend accuracy.