Aluminium sheet metal is exceptionally lightweight, formable, and corrosion-resistant, making it an ideal choice for a wide range of projects. Before these sheets can be used, however, there's often the need for some preparation work. One of the most common processes involved is bending.

Bending is used to achieve the precise shape needed for an application - but with so many different bending techniques available, it's not always easy to know which you should choose for the best results.

If you're curious about the different sheet bending options out there, let the metal experts at Clickmetal guide you through them. Keep reading to discover the most common techniques for bending aluminium sheet metal, the advantages of each, and the applications they're best suited for!

1. Press Brake Bending

This is the most common and versatile technique for bending sheet metal. A press brake uses a punch and die to bend the metal to a specific angle; these can be altered to create different shapes. Press brake bending is accurate and repeatable, making it ideal for:

  • High-volume production: Identical bends can be replicated consistently, which is perfect for mass-produced parts like brackets, enclosures, and chassis.
  • Sharp bends: The punch and die combination allows for creating crisp, defined bends.
  • Multiple bends in one piece: Complex parts requiring various bends at different locations can be efficiently handled with press brake tooling changes.

2. Roll Bending

This technique uses a series of rollers to bend the metal into a curved shape. Roll bending is ideal for creating long, curved pieces of metal. It's also a good option for bending thick pieces of metal that would be difficult to bend with a press brake. Here are some common applications:

  • Curved panels: Roll bending is perfect for applications like roofing panels, cladding materials, and curved ductwork.
  • Cylindrical shapes: Cylindrical tubes and pipes for various applications can be formed efficiently using roll bending.
  • Thick metal sheets: Bending thicker aluminium sheets that would be challenging for a press brake is achievable with roll bending.

3. Rotary Draw Bending

This technique is used to create complex bends in sheet metal. It uses a rotating mandrel to form the metal around a mould. Rotary draw bending is a good option for creating bends with a tight radius, such as:

  • Curved housings: Electronic enclosures or medical equipment housings with complex curves can be formed precisely using rotary draw bending.
  • Conical shapes: This technique is well-suited for creating conical shapes like funnels or lampshades.
  • Tubular components: Bending preformed tubes or pipes into specific shapes is achievable with rotary draw bending.

4. Three Roller Bending

This technique is similar to roll bending, but it uses three rollers instead of two. The third roller allows for more control over the bend, making it suitable for:

  • Variable radius bends: Need a bend that transitions from one radius to another? Three-roller bending allows for that flexibility.
  • Curved channels or profiles: Forming channels or profiles with curved edges is achievable with this technique.
  • Sheet metal with holes or cutouts: Three-roller bending can handle aluminium sheets with pre-existing features as the rollers provide continuous support.

5. Compression Bending

This technique is used to bend sheet metal by compressing it between two dies. Compression bending is a good option for creating sharp bends, but it must be done carefully - incorrect amounts of pressure can damage the surface of the metal. Use it for:

  • Sharp corners in boxes or enclosures: Creating crisp 90-degree bends for boxes or frames is a good application.
  • Sheet metal with stiffeners: Bending sheet metal with pre-existing stiffeners or ribs works well with compression bending.

6. Stretch Forming

This technique is used to create complex shapes in sheet metal by stretching it over a mould. Stretch forming is a good option for creating aerodynamic shapes, such as those used in aircrafts. Its applications include:

  • Aircraft components: Aircraft wing components or other aerodynamic shapes can be formed using stretch forming.
  • Dish antennas: The parabolic shape of dish antennas can be achieved with this technique.
  • Automotive body panels: Complex curves on car hoods or fenders can be formed using stretch forming.

7. Hand Folding

This is a simple technique that can be used to bend thin sheets of metal. It's not as accurate or repeatable as press brake bending, but it can be a good option for small jobs or for bending metal in the field.

To hand fold aluminium sheet metal, you'll need a brake and a mallet. The brake is a lip that is used to bend the metal, and the mallet is used to tap the metal into place.

Here are some good options for hand folding:

  • Thin sheet metal: Ideal for bending very thin aluminium sheets used in applications like flashing or decorative elements.
  • Field repairs: Quick on-site adjustments or minor bends can be done with hand folding tools for maintenance purposes.
  • Prototyping: During the initial design phase, hand folding can be a quick way to test the feasibility of bends before committing to a more complex technique.

Upgrade Your Project With Cut-to-Size Aluminium Sheets From Clickmetal

We hope this guide has equipped you with the knowledge to tackle your next project with confidence. The only thing left to do? Get the best possible results with premium quality, cut-to-size aluminium sheet metal from Clickmetal!

Our sheets come precisely cut to your project's specifications, with tolerances as low as -0, +2mm. We also offer a range of processing options, including bending, to make your life easier.

We process orders within 3-5 business days and ship them out the next working day via our speedy 24-hour courier service, so you can get started in no time.

If you're ready to begin, shop our aluminium sheet metal today!