Metal Bending &
Forming Guidelines
For the fastest and most efficient quotes, you’ll need to know some of the limitations of metal bending.
We are constantly updating our services and tooling. Check in regularly to find out what new and exciting shapes we can form for you.
Setup and Pricing
Our current pricing model shows what our cost is per bend. We offer discounts depending on the number of bends. The price is also dependent on the flange length. These prices are only for our standard tooling. In case your part requires a custom toolset, please reach out to us for more information at support@bolandlaser.co.za
Thickness |
Flange Length |
<20 Bends |
<50 Bends |
50 and more |
| <=6 | <750mm | R 15.00 | R 10.00 | R 8.00 |
| >6 | <750mm | R 20.00 | R 15.00 | R 12.00 |
| <=6 | >750mm | R 25.00 | R 15.00 | R 12.00 |
| >6 | >750mm | R 32.00 | R 23.00 | R 18.00 |
Bending Capabilities
With our current tooling we can bend a wide variety of materials and designs, but there are limits to what we can do.
Up to 120 tons
Metal folding Capacity
1 mm » 12mm
Maximum Thickness
Up to 3000mm
Maximum Bending Length
Design for Bending
Our recommendation is to design your parts in a CAD program for the quickest turnaround. When sending you cut files add any supporting documents like bending angles and if required material brush direction.
Flange and Base
Let’s start by defining some basic terms. Base and flange are two terms you need to know. The flange is the section that will be bent.
Punch and Die
Let’s start by defining some basic terms. Base and flange are two terms you need to know. The flange is the section that will be bent.
Minimum and Maximum Flange Length
This is the minimum overlay of the sheet on the die that is necessary to perform the bending. The minimum flange length is determined by the sheet thickness.
A quick rule of thumb is the flange length needs to be at least 12mm or 4x the material thickness, whichever is greater.
The maximum flange length we can bend is 500mm.
For more detailed information about the minimum flange length, you can download our design guidelines here.
Minimum flange length for Z-Bending
A minimum X-measurement must be taken into account to prevent tool collisions during a “Z-bend”. Currently our tooling allows for minimum leg length of 62 mm.
Maximum bend Angle
This is the minimum overlay of the sheet on the die that is necessary to perform the bending. The sheet thickness determines the minimum flange length.
Currently, our tooling supports a maximum bend angle of up to 90 degrees. Due to the rebound of the material, the sheet must always be bent a bit farther than the angle indicated. The tools have a maximum angle of 85˚, which allows for bends of up to 90˚ when you take the rebound into account. We are however investing in new tooling regularly and this might change. If you require a bending angle over 90 degrees, we can always create custom tooling for your parts. Contact us today to find the right solution for your parts: info@bolandlaser.co.za.
Minimum distance from hole to bend line
Holes larger than 5mm and close to the bend line may get deformed.
The following minimum dimensions should be applied to hole and slot edges from the bent edges to prevent this deformation.
Minimum hole edge from bend face: 2.5 x Material Thickness (MT) + Bend Radius (BR)
Minimum slot edge from bend face: 4 x Material Thickness (MT) + Bend Radius (BR)
If the hole must be close to the bend line a small cut can be put on the bend line. The cut line needs to conform to these minimum specifications:
- Length must at least be the hole diameter (D) or the length of the slotted holes (edge to edge)
- Width should be 0.8 x Material Thickness (MT)
- Cut’s inner radius <1mm
Box sheaped designs
For box-shaped products, the maximum height is 230 mm to avoid colliding with the machine.
U-Channel Bends
When designing channels for bending, ensure that the flange length does not exceed the base with measurement.
Bend Relief Notches
Be sure to leave enough space for bends. When two corners come together the cannot be completely against each other due to our tolerances. We recommend leaving at least 0.5mm space between them.
When bending next to a piece that stays flat a 0.5mm space between the bent surface and the piece that remains flat is recommended.
