Sheet Metal Forming Service

Get custom formed sheet metal parts for rapid prototyping and production in as fast as 3 days.

Certifications ISO 9001:2015 | CTQ Inspections | ISO 13485

What is Press Brake Forming?

Press brake forming is a metal fabrication process that bends flat sheet metal into a final shape using a press brake machine. Force is applied between a punch (upper tool) and die (bottom tool), and linear bends can be made for a variety of metal materials and thicknesses. All brakes are equipped with CNC controllers for precise part positioning and repeatability. Press brake forming works well to create parts that include U-bends, flanges, channels, and internal bends. Lead times for qualifying formed parts are as fast as three days.

Sheet Metal Forming Design Guidelines and Capabilities

Follow these guidelines for formed sheet metal parts to ensure consistent quality and fast production times:

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 the following metal materials for custom-formed sheet metal parts.
Note that based on material thickness, maximum bending capabilities will vary.

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)

*Formed parts made out of Aluminum 6061-T6 require manual review and are not configurable during the quoting process.

Applications for Press Brake Formed Parts

Press brake forming is a commonly used manufacturing process in industries such as energy storage, computer electronics, robotics, medical, and aerospace. Common sheet metal parts fabricated with forming include: