Tube bending is a fabrication process that forms metal pipes into curved shapes and angles. Aerospace, automotive, and construction industries use this process with wire forming to create structural components such as frames and exhaust systems.

The process involves applying pressure to a tube through a die fitted with an appropriate radius to achieve the desired bend. This method allows pipes to be bent to various shapes and angles.

Tube cutting requires great precision and accuracy for successful outcomes, as even miscalculations can lead to misaligned bends or inaccurate measurements. Achieving desired results requires proper equipment and tools. This includes a tube bender, die sets, mandrels, and lubricants. Additionally, the material’s pipe wall thickness must be considered, which can affect the bend angle.

What We’ll Cover:

How Does Tube Bending Help Manufacturers?

This type of bending is an invaluable tool for manufacturers in many industries. Contract manufacturing (or outsourcing) often combines tube bending with robotic welding to manufacture a finished product.

Custom-Shaped Components

With tube bending technology, manufacturers can create custom-shaped components quickly and easily. This entity eliminates the need for manual fabrication processes that are more time-consuming and labor-intensive. Besides that, this process makes it easier to create complex components that would otherwise require multiple parts and additional manufacturing steps. By streamlining the process, manufacturers can save money on material costs and reduce the time needed to create a component.

Flexibility For Usage In Several Industries

It allows for creation of intricate and precise shapes, which can be used in various applications. These include automotive components and chassis, industrial pipes, HVAC systems, medical devices and equipment, aerospace products, furniture designs, architectural elements, and more. Its versatility makes tube cutting an invaluable asset to any manufacturing process.

Types of Tube Bending

Tube bending is used in various applications, and several different bends can be used. Common types of tube bending include,

1) Mandrel Bending

Mandrel bending involves using a mandrel inserted into the tube while it is bent. This mandrel prevents the material from collapsing as it is curved, allowing for tighter bends with smoother edges.

2) Compression Bending

Compression bending uses a compression plate on one side of the bend to help form the tube into the desired shape.

3) Ram-Style Bending

Ram-style bending uses hydraulic pressure to push the tube around a die to form the bend. This is typically used for large-diameter tubes and pipes.

4) Press Bending

Press bending uses a press machine to form the tube into the desired shape. This method is usually used when tight radii are needed or when bends with multiple angles need to be made.

5) Rotary Draw Bending

Rotary draw bending uses a tool to bend the tube around a stationary die. This type of bending is used for tight bends and high-volume production runs.

No matter the type of robotic welding you need, using quality tools and equipment designed specifically for the task is important.

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Top 10 Applications for Tube Fabrication

Popular applications that require tube fabrication include:

1) Heat Exchangers

After bending tubes, they turn into coil shapes for heat exchangers. These exchangers appear in various industries, such as automotive and aerospace, to transfer heat from one surface to another.

2) Medical Devices

Tubes in medical devices create complex shapes like artificial limbs, catheters, and prostheses.

3) Automotive Components

For steel tubing work, tube fabrication is commonly a part of automobile components, such as fuel tanks and air intake systems.

4) Architectural Elements

Tube bending is essential for creating various architectural elements, including handrails, staircases, and furniture.

5) Industrial Components

Tubes advance industrial parts into various components for heavy machinery, from sheet metal fabrication and skip containers to conveyor belts and exhaust systems.

6) Decorative Elements

Tube cutting creates a variety of decorative elements, such as furniture accents and decorative fencing.

7) Storage Tanks

Tubes can form storage tanks for various liquids, including oil and gas.

8) Heat Pipes

Heat pipes are hollow tubes with a working fluid that transports heat from one end to the other.

9) Food Processing Equipment

Tube cutting helps make several components for food processing equipment, such as conveyor systems, blenders, and material handling carts.

10) Aerospace Components

Manufacturers use the tube fabrication process for aerospace components, from satellite antennas to control rods.

With the right tools and expertise, tube fabrication can create components for various industries and applications.

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How to Find a Reliable Tube Fabrication Company

Start your research by reading reviews and asking for referrals from other businesses or professionals in the industry. Make sure that you compare several companies before making a decision.

Once you have sorted and narrowed down your list of potential tube fabrication companies, it is important to ask questions. Their experience, the types of tube materials they use, and the services they provide are some important queries you should keep in mind.

You should also ask for quotes to compare prices and ensure you get the best value for your money. Additionally, it is important to ensure that any potential tube fabrication company has a valid license and is up-to-date on all safety regulations.

It is also a good idea to visit their facilities and talk with staff members to get an idea of the quality of their work and customer service.

Key Takeaways

Tube bending is an invaluable tool for manufacturers that helps them save time and money while creating components of any size or shape.

By streamlining steel tubing work and offering greater flexibility in design, tube fabrication can help manufacturers create higher-quality products faster and more efficiently.

When looking for reliable tube-cutting services, ensure that the process is smooth and doesn’t include any hidden costs to avoid the hassle.

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100% U.S.-Based Tube Fabrication

Above all, we’re here to be your greatest resource in contract manufacturing. We conduct all of our stainless steel wire forming in the heart of New England. Plus, we’re ready to ship anywhere in the U.S.!

Wirefab Inc. has over 65 years of experience in custom sheet metal fabrication as one of New England’s top custom welding service companies. Whether you need custom CNC machininglaser metal cutting, or material handling cartswe’re here to help. Above all, we’re always eager to solve our customers’ problems with a broad range of manufacturing capabilities. Contact us today to see how we can simplify your next project.

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