Precision Engineering: Achieving Superior Results with Custom Aluminum Tube Bending

July 18, 2023

Tube bending is often critical for OEM custom fabrication due to its versatility. The bending process can bend tubes of many different metals into various shapes and sizes to meet your custom needs. The use of dies and mandrels allows for customization and precision.

Triad understands that every project is different. Our expertise and experience make us one of the industry's top tube-bending OEM suppliers. Let us help you find the best aluminum tube bending solution for your custom fabrication today.

Custom Aluminum Tube Bending Advantages

Although many metals are suitable for tube bending, Triad specializes in custom aluminum tube bending. Aluminum offers an exceptional blend of strength and formability. This allows the alloy to bend to your specifications while maintaining its durability.

Aluminum tube bending permits tight radius bends and precise angles, which can create complex shapes and designs. By bending a tube to your requirements, it will be stronger and able to withstand specific environmental stressors.

Aluminum can be bent without compromising the structural integrity of the tube by preventing the development of cracks, kinks, or internal damage.

Aluminum 6061 and Aluminum 6063

Triad provides bent aluminum tubing in aluminum alloys 6061 and 6063, which offer a range of advantages, including:

  • Low melting temperature
  • Low heat capacity
  • Excellent weldability
  • Corrosion resistance
  • Extrudability

Aluminum Tube Bending Methods

There are many processes for bending aluminum tubing. Each method yields different results, so the specifications of your project will determine which process should be performed. These methods produce superior results for your custom aluminum tube bending. 

Compression Bending

Custom compression bending involves clamping the tubing, then pulling it around a bend die to create the desired radius. The die remains stationary, and the tubing does not require a mandrel. Compression bending is straightforward and can be used to create simpler bends quickly.

Rotary Draw Bending

Rotary draw bending involves clamping the exterior of a pipe, then bending it over a die with the same radius as the desired tube radius. This method works well for custom bending applications that require a tighter radius because the die helps prevent the tube from forming an oval shape as it is bent. Rotary bending utilizes mandrels to prevent the tube from collapsing.

Roll Bending

Roll bending utilizes two immobile rollers and a mobile inner roller to bend tubing. The immobile rollers hold the tube securely while the mobile roller forms the metal into a bend. Roll bending is typically used for custom tube bending that requires a larger radius.

Ram Bending

Custom ram bending involves driving a hydraulic ram into short tubing segments braced against a roller. The tube is shifted, and the process is repeated until the desired radius is achieved. Ram bending is the most simple and cost-effective form of tube bending, although there is less control over tight tolerances.

Industries Served

Due to its flexible and precise design, custom aluminum tube bending applies to many industries, including:

  • Medical
  • Automotive
  • Aerospace
  • Construction
  • Manufacturing

Superior Aluminum Tube Bending by Triad for OEMs

Aluminum is lightweight yet sturdy and highly workable, making it a top choice for OEM purposes. With over 40 years of experience, our production capabilities, quality standards, expertise, and customer service have established Triad as a trusted OEM manufacturer in tube bending.

In addition to the general benefits of tube bending, Triad specializes in manual tube bending, the backbone of our quality custom tube fabrication. Without the need to write computer code to run the equipment, manual tube bending offers a faster setup, translating into cost savings for medium quantity runs.

Contact Us for Aluminum Tube Bending Services

Triad Products specializes in medium runs of 100 to 1,000 in aluminum tube bending fabrication. When you combine our manufacturing and assembly capabilities, you can see why OEMs choose Triad Products as their single-source supplier for custom aluminum tube bending. Request a quote or contact us to discuss your project and learn more about our custom aluminum tube bending advantages. 

Example of 6063 Aluminum tubing that was bent, threaded, finished and fully assembled into an adjustable folding bicycle cargo rack.