Aluminum Extrusion Fabrication & Bending

Imagine taking a single aluminum extrusion and adding multiple bends to create a 1-piece frame for the door of a Class 8 truck or forming a hoop for a bicycle wheel rim. Picture adding a gentle sweep to a structural element for office furniture or creating an arch for a new energy-efficient window for a historic building. With the right profile design, the right bending process, and the right experience, even more complex shapes can be bent - often simplifying component design and achieving distinctive aesthetics.

Bending Considerations

Bending needs to be addressed during the component design stage, as alloy selection and heat treatment must be considered. The profile design and desired final geometry will influence the bending process employed and the consideration and management of spring back.

Bending Processes

To meet a variety of final component requirements extruders offer a variety of bending processes:

  • Roller bending (like the illustration at the right) is used to bend extrusions to a large radius and can roll a fully circular part
  • Stretch or rotary draw bending can be used to create more complex, multiple bend parts using CNC control with or without a mandrel
  • Press or ram bending is best for simpler operations. Parts are shaped in a two-part tool with a bending die pushing the profile against pressure dies.

Given the range of processes, it is recommended that you explore your bending requirements with the technical staff of an experienced extrusion bender early in the design process. Find an Extruder can help locate an extruder with the right fabrication experience.

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