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Aluminum Extrusion Bending2024-02-20T03:09:14+00:00

Aluminum Extrusion Bending

Aluminum extrusion bending services are offered by aluminum fabrication company like FONNOV ALUMINIUM.

The extrusion process isn’t enough to meet bending requirements. And for that reason, benders are used to turn these extruded aluminum into curved aluminum extrusions that will allow conversion of simple shapes into complicated ones.

FONNOV ALUMINIUM provides aluminum extrusion bending services in our fabrication factory.

We can custom bend aluminum bars, aluminum extrusions, aluminum tubes (pipes), aluminum channels, aluminum beams, aluminum trims and aluminum structural shapes to meet your specifications.

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aluminum tube bending-fonnovaluminium

Engineers design a variety of aluminum parts according to product needs. These designs usually cannot be achieved simply by aluminum extrusion and require further processing, and bending/curving aluminum extrusion is one of the processes.

LED lamps, armrests, furniture, automation, and frame products require bending technology for their products.

Bending aluminum extrusions involves putting the alloy into a bender. The bender is designed with different shapes. The aluminum assumes the shape of the bender in the end. Aluminum extrusions are bended to suit the clients’ desires. Besides, some designs cannot be achieved if the metal is not bended. In terms of costs, more is involved.

Aluminum tube bending is the most requested service among our customers. This is an example of a 90-degree bent aluminium tube OD38 * 2.5MM.

Contact our consultants for more aluminum extrusion bending service.

Benefits of Aluminum Extrusion Bending

Aluminum extrusion bending has a number of benefits. This explains why it’s a common practice today. Here are other benefits for bending aluminum extrusions.

  • Strengthening

This is one of the reason extruded aluminum is bended. For instance, bended aluminum is combined to form complex shapes that form the foundation of most modern houses today. The irony about this is that the stronger aluminum is the harder it is to bend. And that’s why some shapes are preferred for easy bending.

  • Ability to be creative

Aluminum extrusion bending gives room for creativity. You can come up with different shapes and create a masterpiece. Aluminum extrusion experts that specialize in bending aluminum have time and again made uniquely designed products for their clients. That has seen the customers extremely happy thus urged to come back for more.

  • Enhance functionality

Take a look at how an elevator works. The bending makes the belts work more efficiently and effectively. This is true especially for the longer elevators that move longer distances.

In busy manufacturing companies, there are many bended aluminum extrusions in use. Through the metal, objects and products can be moved with ease. That way, a lot of money is saved from spending for operations and overheads. For an organization, this is a great step in the right direction.

If you save like this continuously, it becomes easy to grow your cash flows. Enhanced functionality also lifts some weight from the employees thus better delivery.


  • Extreme bends may cause the aluminum to break.
  • Sometimes you’ll have to incur additional manufacturing costs.

How to Bend Aluminum Extrusions?

A lot of consideration is put when bending aluminum extrusions. This is because the process can lead to undesirable results if care isn’t taken. But, if everything is considered and all the details included, everything will be well. Below are some of the steps taken to bend extruded aluminum.

  • Rotary Draw Bending

After extrusion, place the aluminum profiles on the bending machine. The next step is to move the bending tool. This ensures that the extruded aluminum is turned into the desirable tool.

The state in which the extruded aluminum is at this time allows the metal to change shapes easily. Once the extruded aluminum has turned into the right shape, it can be left to solidify. After solidifying then the curved aluminum can be dispatched for collection by clients or wholesalers.

  • Pushing Bending

Aluminum extrusion in a bendable state is pushed to the desired shape. This happens under intense pressure. That way, the aluminum profile can fold easily into the shape the bender is intended for. During this process, minimal human labor is required because the bending machine does most of the work.

  • The Three Rolling Bending

There are different types of Aluminum bending techniques. This one is important in the making if complicated shapes like symmetrical structures. For instance, making aluminum symmetrical shapes can be a challenge to say the least. A three rolling bender makes that easy and possible. Besides, it brings up efficiency and that means lesser money is spent during the production process.

  • The Strength Bending

Bending Aluminum extrusion with extended diameters is not an easy undertaking. The technique must be right for the best results to be achieved. That’s why you need specific bending techniques to achieve that. The strength bending technique helps achieve this.

The extruded aluminum is compressed with the edges attached to the bender. Under the high pressure, the middle part of the metal changes shape into that of the bender.

This technique mostly applies to heavy metals that requires high level strength. At the end, you’ll have a bended aluminum extrusion with superior mechanical strength. Such curving aluminum extrusion can be used for different purposes including areas that need strong aluminum.

What Factors Need to Be Considered When Designing the Aluminum Extrusion Bender?

  • Diameters of the extruded aluminum

There are different types of extruded aluminum to be produced. For hollow aluminum extruded tubes, the internal and external diameters of the aluminum tube must be considered. There must be enough to accommodate the aluminum tube.

In a case where this is not considered, the end results might be something far from what was expected. You must keep in mind that a lot of pressure is used in bending aluminum extrusion. If the right diameter is not put on the bender, undesirable results will be achieved.

  • Radii variations

Aluminum expand when heated. This means that aluminum extrusions may change in radii if somethings are not considered. That’s why the bender must be designed well to accommodate possible changes and prevent deformations.

The bender should also be streamlined for this to happen. A streamlined bender will ensure that the bended metal’s radius is standard all through.

Depending on the purpose the hollow metal is made for, such consistency is really important. That’s why the same metal must be designed with the precision it deserves. That way, everything will be in order especially when the metal is in use.

  • Extruded aluminum length

Extruded aluminum have different uses. For some, their length is the most important feature considering their use. That means the bender has to get the height requirements correct. Every inch must be included and none left out.

That means the best designers must be employed to design perfect benders. Length must be thought well about and perfectly fixed. That means each complex shape will have a unique bender to be used in achieving that shape. If another shape is to be achieved, another bender has to be formed. Common aluminum extrusions that should have similar lengths at the end can share a bender.

  • Mechanical strength

Curved aluminum extruded profiles are used for different functions. This means different mechanical requirements come into play. For instance, the construction industry demand mechanically stronger aluminum extrusion profiles.

The diameter of the bender and other details about its length among other factors affect the final mechanical strength of the extruded aluminum. That’s why experts must be involved in its design. That way, a perfect bender will be constructed and the result would be a significantly strong aluminum.

There can be dire consequences if this is not looked into. The bender and die used for bending aluminum extrusion have a major impact on the product you get at the end.

  • Critical surface areas

The extruded aluminum will have specific shapes when bended. Some particular areas of the metal have to be well taken care of.

For instance, the corners of a bended aluminum extrusion shape shouldn’t be too sharp. This will help avoid accidents that would have been catastrophic.

Aluminum Extrusion Bending Thought and Execution Process

For effective bending and execution, there must be a thought process. This will guide the execution and will lead to great work if everything is followed according to plan. Below are some of the considerations to make during these processes.

Design Consideration

Sample a few designers and you’ll get different opinions about bending aluminum extrusion processes. None of them are wrong because they opinionate based on their industrial experience and needs. For instance, the bending requirements for the aerospace industry may not be same as that of the agricultural industry. For that reason, the designs must be done specific to needs of each industry.

When doing large scale projects, it’s important to focus on the alloy to be used, weight, and costs to be incurred. It is to be understood that different alloys will bring out different outcomes. That explains why you need to consult experts of the field you want to supply extruded aluminum with.

Other critical factors to consider include the applications of that curved aluminum you want made. That information helps to shape the details that will be considered when defining curved aluminum extrusion specifications.

Shape complexity is also important to consider. This determines whether the project will be successful or not. Besides, it has a significant impact on the production costs.

Finishing options must also be considered. One may wonder why this should be the case. Well, a superbly finished aluminum will look better and serve longer. That’s value addition and means more satisfied clients.

Another important design aspect is the aluminum’s bendability. It’s easier to bend more bendable aluminum extrusions than the highly resistant ones. This means the bender has to be stronger and more efficient when dealing with less bendable Aluminum extrusions.


Bending aluminum extrusion isn’t the easiest of tasks to do. Balancing sides is even hard. For instance, making a symmetrically perfect shape requires precision and giving attention to detail at the bending point.

The use of asymmetrical metal will surely bring problems during bending. The more asymmetrical side will have severe twists than the symmetrical one. This may bring about some imbalance you don’t want to deal with in the future.

Designing Hollow Sections

It’s two times harder folding hollow sections. The hollow area must be well taken care of to prevent the pressure from folding the aluminum into the space. That means there must be a balance between the external force bending the aluminum tube and that which the inside can handle.

Another common challenge arises in cases where the manufacturer has used square corners. If that’s the case, the pressure from the bender will force the metal to crack. This may mean repeating some extrusion processes to correct the problem. To avoid such, manufacturers ought to use circular corner interiors. That will save the aluminum tube from extreme pressure that may lead to breakages.

There are other alternatives to this. Increasing the metal’s wall thickness is one of them. By doing so, you reduce the tension and pressure reaching aluminum’s interior. There’s also a use of internal support. This helps manage the pressure tending towards the inside of the hollow shape.

Complex Shaping

Extruded aluminum is also used to make channels as well as other complex structures. Shaping these complex products is a process that requires expertise. A significant amount of force is applied to twist the aluminum into channels. The arm exerting the force tends to move in the direction of the central axis. That way, an almost circular shape is made. Sometimes cylindrical aluminum shapes are made out of this action.

If you’ve seen a conveyor belt work, you’ll start to appreciate this process. In most cases, the belt or similar movers are made in this design. This helps smoothen processes in the manufacturing industry and/or transport. It brings about top level efficiency.

When making such products, it’s important to consider the functionality. Once employed for service, a lot of pressure is involved. That means friction will be there and wearing & tearing made inevitable. Quality alloys must therefore be used to minimize the number of maintenance schedules to be done.

Besides, when the friction is too much, the systems are likely not going to last long. That means you’ll have to spend extra money unnecessary calling repair experts to control the damages. That’s why you must get quality aluminum extruded products made of quality to avoid such inconveniences.


There are different techniques used in bending aluminum extrusions. Regardless of the method, the extruded aluminum has to undergone the finishing process before release to the purchaser. Some of the things aimed at during the finishing process is just to make the metal appealing to the eye.

The finishing process is more of aesthetic. After this process, the curved aluminum extrusion profiles will be ready for delivery. At that point, the company will make sales as the buyers scramble to collect their orders. This process is also fairly costly. But the costs are subject to the manufacturer you’re dealing with.


Aluminum Extrusion Bending FAQs

What is the smallest aluminum extrusion that can be bent?2023-10-11T08:45:20+00:00

There may not be a universal smallest aluminum extrusion profile that can be bent because the project requirements and the tools available are widely varied. CONTACT US to know more if you have a request of bending small aluminum extrusion.

What is the largest aluminum extrusion profile that can be bent?2023-12-05T03:02:38+00:00

Large aluminum extrusions may require specialized dies, a powerful bending machine, preparation, and good fixturing to execute. We can’t specify the exact largest aluminum extrusion profile that can be bent.  CONTACT US to know more if you have a request of bending large aluminum extrusion.

What is the best way to bend round aluminum tubing?2023-10-11T08:11:29+00:00

The best way to bend round aluminum tubing is by cold forming. This is where the tubing is put in a CNC tube bending machine or any other appropriate setup and bent under room conditions. For thin-walled tubing that is likely to flatten or form wrinkles, the sand-packing method may be applied.

Which aluminum alloy is the best for formability?2023-10-11T08:04:56+00:00

Several aluminum alloys fall in the formable category, but the best choice is aluminum alloy 3003. Although the alloy’s strength is not that impressive, this material would suit projects where bendability is the main consideration. Other formable alloys that come close are 5052, 6063 and 6061.

  • Is 1xxx aluminum extrusion good for bending?

Yes, this extrusion material is good for bending. It is pure aluminum, thus extremely ductile, but with no structural value.

  • Is 2xxx aluminum extrusion good for bending?

No, 2024 aluminum extrusion is not good for bending. This is one of the strongest series so it wouldn’t perform well in a bending project.

  • Is 3xxx aluminum extrusion good for bending?

Yes, 3003 aluminum extrusion is good for bending.

  • Is 5xxx aluminum extrusion good for bending?

Yes, 5052 and 5083 aluminum extrusion is good for bending.

  • Is 6xxx aluminum extrusion good for bending?

Yes,  aluminum extrusions with alloy 6063, 6061, 6005, 6060 and 6082 are all good for bending.

  • Is 7xxx aluminum extrusion good for bending?

No, 7075 aluminum extrusion is not good for bending. Like the 2xxx series, this series is extremely strong, so it cannot bend easily.


How to design for aluminum extrusion for bending?2023-10-11T08:07:02+00:00

Designing for aluminum extrusion for bending entails considering a few things and following some steps. Here is an overview of this design process:

  • Choose the most suitable aluminum alloy for bending
  • Determine the most optimum thickness
  • Choose the die design according to the project requirements
  • Determine the bending radius
  • Decide whether the surface is smooth enough for bending
  • Identify the heat treatment to be used, if necessary
What are the potential defects arising in the manufacture of curved profiles?2023-10-11T07:50:56+00:00

As significant forces of torsion, compression, and tension are subjected to the aluminum concurrently, it is expected cracking, deforming, and other defects may occur. To avoid these challenges, the designer should suggest profiles that generate as minimal stress as possible.

Why is it important to bend aluminum extrusions?2023-10-11T07:37:14+00:00

It is important to bend aluminum extrusion to achieve further use. These include angles, curves, and other shapes as may be required in manufacturing. Bending also makes it possible to join different aluminum extrusion sections. Bending aluminum extrusions makes them versatile for use in different projects. It could be for doors, windows, decorations, vehicles, or other structures.

What are the different methods of bending aluminum extrusions?2023-10-11T07:56:22+00:00

Popular methods of bending aluminum extrusions are rotary draw bending, stretch bending, compression bending, and roller bending. Others are ram bending and free-form bending.

Rotary draw bending uses a rotating die that achieves accurate angles. It is ideal for larger aluminum extrusions.

Stretch bending is also referred to as tensile bending, a name related to the type of force that is predominant in this process. Its bending die may be expensive, but the process achieves different shapes without subjecting the extrusion to a lot of surface damage.

For compression bending, a compression die works together with a fixed bending die to achieve the desired profile. It is suitable for higher volumes, but the risk of deformation is high.

The roller bending method, as the name suggests, incorporates a set of rollers. It is one of the most common methods of bending aluminum extrusions.

While the ram bending method is probably the most straightforward, free-form bending is highly advanced.

What is the wrapping bending technique? Advantages? Disadvantages?2023-10-11T08:51:12+00:00

As the name suggests, wrapping bending involves the wrapping of the aluminum extrusion profile around a form so that the extrusion acquires the shape of that form. The advantages of wrapping bending are simplicity, versatility regarding the radii, and cost-effectiveness. It has disadvantages such as not being able to produce complex shapes, inaccurate bends, and poor surface finish.

What is the mandrel bending technique? Advantages? Disadvantages?2023-10-11T08:48:12+00:00

This is a bending technique that suits a thin-walled aluminum extrusion profile. It is characterized by the introduction of a mandrel or internal support for the aluminum tube. The advantages of the technique are the accuracy of the process, speed, and maintenance of the tube roundness. The disadvantages of mandrel bending are a lengthy setup time and high cost.

What is three roll bending technique? Advantages? Disadvantages?2023-10-11T08:14:43+00:00

This is a cold bending technique whereby the aluminum extrusion is passed through three adjustable rollers to bend it. Its advantages are that it can achieve a range of radii and can bend different types of sections. Disadvantages include relative inaccuracy, poor repeatability, and slowness.

What is the push bending technique? Advantages? Disadvantages?2023-10-11T08:50:30+00:00

Push bending by another name is ram bending. It comprises a ram and pressure dies. The ram pushes the aluminum extrusion against the pressure dies to form the desired bend. The advantages of the method are speed, cost-effectiveness, and speed. A major disadvantage is inaccuracy.

What kind of extruded aluminum should you go for?2022-04-08T07:17:37+00:00

The best option to go for is the aluminum tubes, aluminum channels, aluminum beams. This unique option has benefits over other extruded aluminum. It’s strong and reliable. This means you can make good and complex structures out of this metal. The products can sell well and keep the company competitive.

Besides, aluminum tubes, aluminum channels and aluminum beams are known to make reliable shapes. For that reason, you too can use this option when working on a project. The reliability is like no other.

How do you manually bend aluminum extrusion?2022-04-08T07:14:51+00:00

There are different options to bending aluminum extrusions. Each option has advantages and disadvantages as well as its challenges.  That’s why you have to evaluate deeply both options and see which one suits your needs.

Manual bending of aluminum extrusion requires a lot of energy. Keep in mind extruded aluminum is very strong and bending may not be easy. To achieve this, you should use aa strong bender that will move the metal into shapes that you want.

This can be done with the support of human labor. That means you will incur more in terms of overhead costs. The good thing about this is the fact that you can create unique shapes that some machines cannot. The only downside is the fact that it may take time before completing a project.

Does bending weaken Aluminum?2023-05-04T04:12:28+00:00

Bending may or may not strengthen the aluminum alloy. In other cases, the reverse is true. Bending can also lead to the weakening of aluminum alloys. This is dependent on conditions to which the metal is exposed to. If they’re extreme, you can be certain the metal will be weakened.

On the flipside, the right conditions will make the aluminum stronger if exposed to bending. Therefore, the question of strengthening or weakening aluminum is subject to the environment you expose the metal to.

Browse FONNOV Aluminium Categories

Standard & Custom Aluminum Extrusions

  • Aluminum Rods (Round Bars)

  • Aluminum Flat Bars
  • Extruded Aluminum Angles

  • Extruded Aluminum Beams
  • Extruded Aluminum Channels
  • Extruded Aluminum Trims

Custom Aluminum Extrusions For General Industries

  • Aluminum Extrusions for Vessels and Boats

  • Aluminum Extrusions for Airport

  • 5083 Aluminum Extrusions

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