01
Are your bend angles drifting?
Springback in 5052 or 304 stainless pushes angles off by 1–2°. The part looks fine on the bench and fails at assembly. Rework means a second setup and a lost day.
Sheet Metal Fabrication
Metal Bending Metal Parts
Custom sheet metal bending for brackets, enclosures, and chassis. We work from 0.5 mm to 6 mm stock in aluminum, stainless, and steel. One prototype or 10,000 parts.
±0.05 mm for formed features3–5 day shippingNo minimum orderISO 9001:2015
±0.05 mmTypical formed-feature tolerance
0.5–6 mmSheet thickness range
127CNC machines across 3 plants
12 hQuote and free DFM analysis
Common problems
When bending goes wrong
Most bending defects come from four places. Each one costs time.
02
Do pierced holes stretch near the bend?
If the hole sits closer than 2× material thickness to the bend line, the punch pulls the edge out of round. Bolts no longer sit flat. The fix usually means moving the hole in the drawing, not hitting it harder.
03
Does the finish crack at the radius?
Powder coat over a tight bend cracks along the outer fiber, especially on 6061-T6. The part passes incoming inspection and fails in the field. Grain direction and bend radius both matter here.
04
Are flat patterns off by a few tenths?
Wrong K-factor assumptions throw every downstream feature out of position. One wrong flat pattern wastes a full sheet and delays the whole order. We verify the first article before running the rest.
How we bend
Press brake work built around your drawing
Tooling, bend sequence, and flat pattern all get checked before the first part runs.
Forming capability
Press brake capacity and tooling
We run CNC press brakes with segmented tooling for boxes, channels, and Z-sections. Material thickness runs from 0.5 mm to 6 mm. Maximum bend length reaches 4,000 mm on our long-bed machines.
Die selection follows the inner radius on your drawing. For 1 mm mild steel, a 6 mm V-die gives a clean 1 mm inside radius. Tighter than that and the punch marks the surface. We will tell you when the radius on the print cannot be formed as drawn.
- 1Segmented punch and die setsHandles box bends and return flanges without custom tooling.
- 2Backgauge repeatabilityHolds flange lengths within ±0.1 mm across a run.
- 3Bend simulationSequence checked in software before the first blank is cut.
From drawing to part
Flat pattern, prototype, then production
Laser cutting and punching create the blank. We calculate the flat pattern from your 3D model using the correct K-factor for the material and tooling. For 6061-T6 at 2 mm, that is not the same number as 304 stainless at 2 mm.
The first article gets measured on a marble platform with height gauges and calipers. If the angle or flange length sits outside the print, we adjust the program before cutting the rest. Production runs use the same setup, so part 500 matches part 1.
- 1Free DFM checkWe flag holes too close to bends and radii that will crack.
- 2First-article inspectionAngles and flange lengths recorded before the run continues.
- 3One setup for the whole orderNo re-hitting between the prototype and the batch.
Material guide
Bend behavior by material
What to expect before you send the print.
| Material | Forming notes | Typical use |
|---|---|---|
| 6061-T6 aluminum | Cracks at tight radii; anneal or use 5052 | Brackets, panels |
| 5052 aluminum | Bends well to 1× thickness radius | Enclosures, covers |
| 304 stainless | High springback; overbend needed | Food and medical equipment |
| 1018 mild steel | Predictable; standard V-die works | Chassis, frames |
| C260 brass | Good formability; watch surface marking | Electrical contacts |
| 6063 aluminum | Soft; dents easily during handling | Extruded frames |
What we do
Sheet metal services under one roof
Bending is one step. We handle the rest so parts arrive ready to assemble.
01
Laser cutting
Fiber laser cuts blanks up to 4,000 mm with clean edges ready for forming.
02
Press brake bending
CNC press brakes with segmented tooling for boxes, channels, and complex profiles.
03
CNC machining
Milled slots, tapped holes, and counterbores added after forming when needed.
04
Welding and assembly
MIG, TIG, and spot welding for frames and enclosures, with fixture-checked squareness.
05
Surface finishing
Anodizing, powder coating, plating, and laser marking applied after all forming.
06
Inspection and packing
100% inspection before shipment. Parts packed to avoid transit damage.
Scope
Bending scope and limits
| Item | Range | Notes |
|---|---|---|
| Sheet thickness | 0.5–6 mm | Thicker stock quoted on review |
| Maximum bend length | 4,000 mm | Long-bed press brakes |
| Formed-feature tolerance | ±0.05 mm | Typical, depends on feature |
| Minimum flange height | 3× thickness + radius | Below this, tooling marks appear |
| Hole-to-bend distance | 2× thickness minimum | Closer holes deform during forming |
| Surface finish after forming | Ra 0.8–1.6 μm | On machined features |
| Order quantity | 1 to 10,000+ | No minimum order quantity |
Why GreatLight
What you get with every order
15Y
Forming since 2011
Fifteen years of press brake work across 3 wholly-owned plants in Dongguan and Singapore.
±0.005 mm
Machining tolerance
When bending is followed by CNC work, milled features hold ±0.005 mm on the same part.
99.99%
Qualification rate
Parts that pass final inspection on the first submission, tracked across production runs.
12 h
Quote turnaround
You get a quote and a free DFM analysis within 12 hours of sending the drawing.
24 h
Production start
Once the order is confirmed, cutting and forming can begin within 24 hours.
100%
Inspection before shipment
Raw material check, in-process monitoring, final inspection. Reports on request.
7,600 m²Manufacturing space
150Technicians on staff
4ISO certifications held
< 2%Historical late-delivery probability
Industry results
What different industries require
Automotive and EV
Battery trays and brackets need flatness after welding. We fixture-check squareness before finishing.
- IATF 16949
- ±0.05 mm formed features
Industrial machinery
Control cabinets and mounting frames require consistent bend angles across long runs.
- 4,000 mm bend length
- 100% inspection
Electronics enclosures
Chassis and RF shields need tight hole-to-bend control so boards drop in without rework.
- 2× thickness hole rule
- Ra 0.8–1.6 μm
FAQs
Questions engineers ask before ordering
What bend radius can you form in 6061-T6 aluminum?
A safe starting point is 2–3× material thickness for 6061-T6. Tighter than that and the outer fiber cracks, especially across the grain.
If your design needs a tight radius in 6061-T6, we will flag it in the DFM review. Switching to 5052 or forming in the annealed condition usually solves it.
How close can a hole sit to the bend line?
Keep pierced holes at least 2× material thickness from the inside bend line. Closer than that and the hole distorts during forming.
If the layout will not allow it, we can pierce after bending or add a relief notch. Both add a step, so it helps to know early.
What tolerance can you hold on bent parts?
Formed features typically hold ±0.05 mm. That covers flange length and hole position after bending.
Bend angle itself depends on material and radius. Springback varies between alloys, so we compensate in the program rather than promising a fixed angle tolerance for every material.
Should I anodize before or after bending?
Always after. Anodizing and powder coating both crack if the part is formed afterward.
We complete all cutting, forming, welding, and machining first, then send the parts for finishing. That keeps the coating intact at every radius.
Do you offer a minimum order quantity?
No. We run from one prototype to 10,000+ part runs on the same equipment and setup.
For prototypes, the first article is inspected and recorded before any batch work starts. That record carries over if the design moves to production.
How do you check bend angles before shipping?
Parts are measured on a marble platform using height gauges, micrometers, and go/no-go gauges. Flange lengths and angles are recorded on the inspection sheet.
We inspect 100% of parts before shipment. Inspection reports are available on request with the order.
Can you form parts longer than 2,000 mm?
Yes. Our long-bed press brakes handle bends up to 4,000 mm. That covers full-length channels, rails, and large enclosure panels.
For very long parts, we check straightness after forming. Long flanges can bow if the tooling is not aligned, so we verify before the run continues.
What do you need to quote a bending job?
A 3D model or a 2D drawing with bend lines, material, thickness, and finish marked. Quantity and any critical dimensions help too.
Send the files and we return a quote with a free DFM analysis within 12 hours. Uploads stay confidential, and we sign an NDA on request.
Send your drawing, get a quote in 12 hours
Upload a 3D model or 2D print. We review the bend radii, hole placement, and material before quoting, so the price reflects a part that can actually be formed.
12-hour quote100% inspectionNo minimum orderNDA on request
