What is Press Brake Forming?

Press brake forming is a metalworking process where flat sheet metal is bent into a specific shape using a press brake machine. The process involves applying force between an upper punch tool and a lower die, creating precise linear bends in various metal materials and thicknesses. CNC controllers are used for accurate part positioning and consistent results. This technique is ideal for producing parts like U-bends, flanges, channels, and internal bends. The lead time for qualifying formed parts can be as quick as three days.

Design Guidelines and Capabilities for Sheet Metal Forming

Adhering to these guidelines for sheet metal forming will help guarantee high-quality results and quick turnaround times for your projects.

Maximum Bend Length 47 in.
Minimum Qualifying Part Size 0.05 in x 0.05 in (12.7mm x 12.7mm) for formed parts
Maximum Pressing Force 80 tons
Bend Angles 1 degree ‘kick’ to 135 degrees
Bending Output Linear bends—external and internal flanges
Maximum U-Channel Ratio 2:1 (width:height)
Internal Radius Tooling Options 0.01 in. to 1 in. (standard tooling increments) >1 in. radius bends will be bump formed
Offsets Standard offset tooling sizes
Hems Closed hems up to 47 in., open hems up to 36 in.
Forming Best Practices
  • Relieve bends in CAD designs
  • For best price and lead time, use manufacturer-recommended radius tooling
  • Ensure appropriate placement of nearby features (e.g., holes, hardware inserts, other bends)

Sheet Metal Materials and Thicknesses for Formed Parts

We offer a variety of metal materials for custom-formed sheet metal parts. Keep in mind that the maximum bending capabilities will differ based on the thickness of the material selected.

Material Grade Thicknesses Available
Aluminum
  • 5052-H32
  • 6061-T6 (requires review)
  • 5052: 0.025 in. – 0.250 in. (0.635mm – 6.35mm)
  • 6061: 0.025 in. – 0.134 in. (0.635mm – 3.40mm)
Steel
  • CRS/HRPO
  • Galvanneal (pre-plated)
  • Galvanized (pre-plated)
  • CRS/HRPO: 0.025 in. – 0.250 in. (0.635mm – 6.35mm)
  • Pre-plated: 0.025 in. – 0.134 in. (0.635mm – 3.40mm)
Stainless Steel
  • 304-2B
  • 304-#4
  • 316-2B
  • 304-2B: 0.025 in. – 0.250 in. (0.635mm – 6.35mm)
  • 304-#4: 0.025 in – 0.119 in. (0.635mm – 3.023mm)
  • 316-2B: 0.025 in. – 0.134 in. (0.635mm – 3.40mm)
Copper
  • C1010
  • C1100
  • 0.025 in – 0.125 in. (0.635mm – 3.175mm)
Brass
  • C260
  • 0.025 in. – 0.125 in. (0.635mm – 3.175mm)

Parts formed from Aluminum 6061-T6 require a manual review and cannot be configured during the quoting process.

Applications of Press Brake Formed Parts

Press brake forming is widely utilized across various industries, including energy storage, electronics, robotics, medical, and aerospace. Typical sheet metal components produced through this process include:

  • Brackets
  • Busbars
  • Covers
  • Panels
  • Mounts
  • Housings or enclosures