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CNC Machining for Aerospace

The extremely high level of precision needed within the aerospace industry makes CNC machining a suitable manufacturing process for the sector.

 

This article provides you with a complete guide to aerospace machining and its importance.

 

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CNC Machining eBook

If you want to produce high-quality machined parts with a sleek appearance, it’s essential to consider some critical factors related to CNC machining. 

 

Here, we’ve gathered some basic information and important considerations to help you achieve the desired results.

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Instant Quote for Sheet Metal Fabrication and New Homepage

Exciting news from RapidDirect!  We’ve rolled out two exciting updates to enhance your manufacturing journey. 

  • Instant Quote for Sheet Metal Fabrication
  • A brand-new Homepage Experience

Custom Sheet Metal Bending Services

Custom metal bending services for high-quality prototypes and production bends. Free sheet metal quote with DFM review within 1 day. Lead time as fast as 3-5 days.
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High Quality
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Our team of experienced engineers utilizes the latest metal bending technology and rigorous quality control measures to ensure that every bent metal part meets the most exacting standards.
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Fast
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Our CNC bending equipment, coupled with streamlined workflows, allows us to turn around your custom bent parts in record time.
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Our experts guide you through the best choices for your project, from selecting materials to choosing bending methods, making sure you get optimal results every time.

What is
Metal Bending?

metal-bending

Metal bending is a fabrication process that involves deforming metal into a specific angle or shape using mechanical force. This process is essential in manufacturing components with precise angles and curves, making it indispensable for creating durable and functional parts across various industries.

At RapidDirect, our sheet metal bending services meet the diverse needs of our clients, whether for simple or intricate designs. Our machinery includes advanced electric and hydraulic press brakes that ensure precision bending, even for parts with tight tolerances. Instantly accessible quotes are available through our user-friendly platform, where you can upload your 3D CAD files to receive an immediate estimation. This streamlined process saves you time and simplifies your journey from design to production efficiently.

Our capabilities go beyond just bending; we offer extensive post-processing options, ensuring that the parts you receive are not only perfectly bent but also ready for immediate application in either prototypes or final products.

How does Metal Bending Work?

The bending process is a fundamental method in metal fabrication that involves deforming metal into a desired shape by applying force, typically through a press brake or similar machine. This process allows for the precise forming of metal along a straight line to create V, U, or channel shapes in sheet metal. The metal bending process can vary from manual methods to advanced CNC (Computer Numerical Control) systems, which offer enhanced precision and repeatability.
 
During the metal bending process, a piece of sheet metal is placed between a punch and a die set. The punch forces the metal into the die cavity, bending it to conform to the die’s shape. Key parameters in this process include the bend angle, radius, and the bending force applied, which can be adjusted to manipulate the metal’s final form without altering its thickness significantly. Material properties such as ductility and thickness also play a critical role in determining the ideal bending conditions.
 
This metal bending fabrication technique is widely used due to its ability to produce strong, functional parts efficiently. Applications range from creating small components like brackets to large architectural features. With advancements in CNC technology, complex and highly accurate bending tasks are now more achievable than ever, allowing for greater design flexibility and faster production cycles. Additionally, CNC systems offer the capability to handle mass production with minimal variation, ensuring consistent quality across large batches.
sheet metal bending
materials

Metal Bending Surface Finish

At RapidDirect, our surface finishes enhance the durability and appearance of bent metal components, meeting the high standards required by diverse industries.

As machined finish leaves the surface straight from the CNC machine, providing a cost-effective option with tool marks.
Anodizing increases corrosion resistance and wear properties, while allowing for color dyeing, ideal for aluminum parts.

Polishing

Ra0.2 (Mirror polish)
Polishing achieves a high gloss finish, reducing surface roughness and enhancing the aesthetic appeal of metals.
Sand blasting uses pressurized sand or other media to clean and texture the surface, creating a uniform, matte finish.
Tumbling smooths and polishes small parts by friction and abrasion in a barrel, offering a consistent but slightly textured finish.
Electropolish is a chemical process that smooths and brightens surfaces while improving corrosion resistance.
Alodine coating provides corrosion protection and improves paint adhesion, mainly used on aluminum surfaces.
Heat treatment alters the mechanical properties of metal to increase its hardness, strength, or ductility.
A brushed finish creates a unidirectional satin texture, reducing the visibility of marks and scratches on the surface.
Powder coating applies a thick, wear-resistant layer with excellent color and texture options, suitable for a variety of surfaces.
Electroplating bonds a thin metal layer onto parts, improving wear resistance, corrosion resistance, and surface conductivity.
Black oxidize is a conversion coating for ferrous metals that improves corrosion resistance and minimizes light reflection.

Metal Bending
Capabilities

Description
Maximum Part Size1.5 m x 1.5m
Metal Bending ForcesUp to 1000 tons
Bending Line LengthUp to 7200 mm
Bending ThicknessUp to 60 mm
General TolerancesOur metal bending standards depend on ISO 2768.
Bend to edge/hole, single surface+/- 0.254 mm (+/- 0.010 in.)
Bend RadiusBe equal to material thickness
Bend Angle+/- 1°
Bend Cutting AreaUp to 4000 mm
Lead Time5 days or more

RapidDirect Metal Bending Workshop

Metal bending transforms flat sheets into 3D shapes through precision force application, using advanced machinery to enforce bends at designated angles. Before bending, the flat sheet must be prepared using cutting methods like laser cutting, which ensures high precision. At RapidDirect, our process leverages high-tonnage equipment, capable of exerting up to 200 tons, to handle materials with a length of up to 3200mm. Each bend is executed with an exact mold ranging from R3 to R50, ensuring accuracy with a machining tolerance of ± 0.1mm. This precision sheet metal bending process is suitable for various applications, from machinery components to custom furniture. Additionally, our custom metal bending services enable us to offer tailored solutions with high precision and consistency.
 

To truly appreciate the sophistication of our operations, we invite you to watch a video tour of our facility.

700+

Sets of Machine

120+

Countries Shipped

20,000+

Customers Served

Advantages of Bending Manufacturing

Metal bending manufacturing is integral across multiple sectors due to its distinct advantages:

  • Cost Efficiency: Metal bending reduces the need for multiple parts and welds, minimizing labor and material costs. By simplifying designs into single, continuous pieces, it helps reduce assembly time and overall project expenses.
  • Enhanced Strength: Bending metal increases its strength along the bend, making the finished parts more durable and capable of withstanding greater loads. This intrinsic reinforcement allows for lighter and thinner constructions without compromising structural integrity.
  • Precision and Flexibility: Advanced CNC bending technology provides high precision and repeatability, ensuring each part meets exact specifications. The versatility in bending various metals like aluminum, steel, and copper allows for broad application across different projects, from industrial machinery to custom automotive components.
  • Aesthetic Improvement: Metal bending techniques can produce clean, attractive lines and curves that enhance the aesthetic appeal of parts. This is particularly beneficial in visible components, such as fixtures and furniture, where appearance is as crucial as functionality.
  • Rapid Production: The speed of CNC bending processes significantly shortens production cycles, enabling faster turnaround times from design to completion. This rapid production capability is ideal for industries requiring quick responses to market demands.

Applications of Bent Metal Parts

Bent metal parts serve a multitude of purposes, transforming sheets into durable, functional components with a wide range of applications:

  • Enclosures and Casings:Custom bent enclosures house everything from electronics to industrial machinery, offering protection and support while maintaining accessibility and aesthetics.

 

  • Brackets and Mounts:Precision bending creates sturdy brackets and mounts used in mounting systems, which are essential for securing components in both commercial and residential settings.

 

  • Panels and Doors:From aesthetic architectural panels to functional doors and barriers, bending metal provides the necessary customization to fit specific dimensions and designs.

 

  • Frames and Beams: Structural frames and beams benefit from the rigidity and strength that metal bending imparts, essential for supporting structures in construction and automotive frameworks.

 

  • Complex Geometries:Advanced CNC bending technology allows for the creation of components with complex geometries, which are crucial for modern designs and applications requiring high precision and unique shapes.

FAQs

The bending process is a fundamental method in metal fabrication that involves deforming metal into a desired shape by applying force, typically through a press brake or similar machine. This process allows for the precise forming of metal along a straight line to create V, U, or channel shapes in sheet metal. The technology employed can vary from manual methods to advanced CNC (Computer Numerical Control) systems, which offer enhanced precision and repeatability.

 

During bending, a piece of sheet metal is placed between a punch and a die set. The punch forces the metal into the die cavity, bending it to conform to the die’s shape. Key parameters in this process include the bend angle, radius, and the bending force applied, which can be adjusted to manipulate the metal’s final form without altering its thickness significantly.

 

This manufacturing technique is widely used due to its ability to produce strong, functional parts efficiently. Applications range from creating small components like brackets to large architectural features. With advancements in CNC technology, complex and highly accurate bending tasks are now more achievable than ever, allowing for greater design flexibility and faster production cycles.

Choosing between bending and welding depends on the specific requirements of a project, including strength, aesthetics, production speed, and cost. Bending is often favored for its ability to create clean, continuous lines without seams or joints, which can enhance both the structural integrity and visual appeal of a part. This method is also typically faster and more cost-effective than welding, as it reduces the need for additional materials like fillers and does not require the energy costs associated with welding equipment.

 

On the other hand, welding is indispensable when complex shapes or sizes, which are beyond the capabilities of bending techniques, are required. It allows for the joining of different materials and the construction of frameworks that bending alone cannot achieve. Welding also provides the strength needed for demanding applications, such as in heavy industrial machinery and structural engineering.

The typical lead time for producing bent sheet metal parts can vary significantly depending on several factors including the complexity of the parts, the volume of the order, the type of metal being used, and the current workload of the manufacturing facility. Generally, simpler bending operations with standard materials can be completed relatively quickly, often within a few days. For standard orders with straightforward specifications, RapidDirect provides a turnaround time from 3 to 5 business days.

 

However, for more complex parts that require multiple bends, special materials, or finishes, the process can take longer. Projects that necessitate custom tooling or extensive pre-production design work can extend lead times further, potentially to several weeks. Additionally, the efficiency of the CNC bending equipment and the capacity of the manufacturing system play critical roles in determining the speed of production.

 

RapidDirect can offer expedited services at an additional cost for projects that require a faster turnaround. Communication with the service provider early in the design process can help ensure that timelines are met and that any potential delays are managed effectively.

The tolerance of bent parts refers to the acceptable deviation from the specified dimensions that can occur during the bending process. These tolerances are critical in ensuring that the parts fit properly in their intended assembly and perform their function as expected.

 

For standard sheet metal bending, tolerances typically range from ±0.1 mm to ±0.5 mm. However, the specific tolerances can vary based on several factors including the type of metal, the thickness of the sheet, and the complexity of the part design. Thinner metals may exhibit greater variability due to their increased flexibility and susceptibility to springback—a phenomenon where the metal tries to return to its original shape after bending.

 

Advanced CNC bending machines can achieve very precise tolerances by precisely controlling the angle and position of the bend. For critical applications requiring extremely high precision, such as in aerospace or medical devices, tolerances might be even tighter, often within the range of ±0.01 mm to ±0.1 mm.

 

RapidDirect will carefully consider the bending method and tooling to match the required tolerances for the application, ensuring optimal performance and fit of the bent parts.

Die marks on bent metal parts are often a concern in metal fabrication due to their potential impact on the appearance and integrity of the finished product. These marks are impressions or abrasions made by the die on the metal surface during the bending process. Whether die marks are visible on the finished parts depends on several factors, including the type of metal, the condition of the bending tools, and the bending techniques used.

 

Soft metals like aluminum are more susceptible to showing die marks because they are easier to indent or scratch. However, using well-maintained tools and applying protective films during bending can minimize these marks. Moreover, manufacturers can employ rubber or urethane pads that act as a buffer between the die and the metal, significantly reducing the likelihood of marking.

 

For applications where aesthetics are crucial, post-processing steps such as sanding, polishing, or painting can be used to eliminate any visible die marks. Thus, while die marks can be a concern, various strategies and techniques are available to manage and mitigate their appearance on bent metal parts.

Yes, there is a maximum thickness for sheet metal that can be bent, which largely depends on the type of bending machine used and the material properties of the metal. Generally, the capacity to bend metal sheets is determined by the tonnage of the press brake and the length of the bend. Higher tonnage machines can handle thicker materials, but there are practical limits based on the metal’s type and the desired bend angle.

 

For common materials like aluminum and mild steel, many standard press brakes can bend sheets up to about 0.5 inches (12.7 mm) thick. However, for tougher materials like stainless steel, the maximum thickness typically decreases due to the material’s higher tensile strength, which requires more force to bend. For these types of metals, thickness might be limited to around 0.375 inches (9.5 mm).

 

It’s also important to consider the bend radius; thicker metals require a larger radius to avoid cracking or breaking during the bending process. Manufacturers need to balance machine capabilities, material characteristics, and design requirements to determine the feasible maximum thickness for any given bending project.

Among commonly used metals in fabrication, stainless steel typically offers the highest resistance to bending. This resistance is primarily due to its high tensile strength and hardness, which make it more challenging to deform compared to metals like aluminum or mild steel. The composition of stainless steel, which includes significant amounts of chromium and nickel, not only provides excellent corrosion resistance but also contributes to its stiffness and durability.

 

The high resistance of stainless steel to bending requires more force to shape, often necessitating the use of press brakes with higher tonnage capabilities. Additionally, due to its tough nature, proper tooling and techniques must be employed to prevent damage to the machinery or the workpiece itself, such as cracking or brittleness at the bend.

 

This characteristic makes stainless steel ideal for applications where structural integrity and durability are paramount, such as in medical devices, food processing equipment, and marine applications. However, the increased difficulty in bending can also lead to higher manufacturing costs and more complex processing requirements.

The bend rule for sheet metal dictates that the minimum bend radius should equal the thickness of the sheet. For instance, if the sheet thickness is 1 mm, the smallest allowable bend radius should also be 1 mm. This ensures proper bending without compromising the material’s integrity.
Common types of sheet metal bending include air bending, bottoming, coining, roll bending, and V-bending. Air bending involves forming the metal with a punch that does not contact the bottom of the die, allowing for flexibility in bend angles. Bottoming provides more precise angles by forcing the material into the die, while coining compresses the metal for exact bends. Roll bending is used for creating curves or circular shapes, and V-bending utilizes a V-shaped die for efficient bending of various angles. Each method is selected based on the specific material properties, thickness, and desired bend angle for optimal results.
Aluminum is frequently considered the easiest sheet metal to bend due to its softness and ductility, which allows for more straightforward manipulation. Thin gauges of aluminum can be bent with minimal effort, making it ideal for various applications, including fabrication and prototyping. Additionally, aluminum’s resistance to cracking during bending enhances its workability, making it a popular choice among manufacturers and DIY enthusiasts alike.
Yes, you can request custom bend angles tailored to your specific project requirements. We provide flexible bending solutions that accommodate various angles and dimensions to suit your needs. Our team works closely with you to ensure the final product meets your exact specifications.
RapidDirect maintains quality by utilizing advanced CNC bending technology, which ensures precision and consistency in every part produced. Our process includes rigorous inspections at multiple stages, checking for accuracy in dimensions and alignment. Additionally, we adhere to strict industry standards, guaranteeing that each bent part is durable and reliable for its intended application.

Laser Cutting
Resources

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RapidDirect x Rennteam Stuttgart: Innovation Collaboration of Racecar Engineering
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RapidDirect x Rennteam Stuttgart
RapidDirect x Rennteam Stuttgart: Innovation Collaboration of Racecar Engineering
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