Design Smarter for Press Brake Forming: Save Time and Money with Accurate CNC
For better manufacturability, lower costs, and shorter lead times, it is important to consider three key aspects when designing parts for press brake forming: part size, number of bends, and feature placement.
At Accurate CNC, our new ACCURL 5-Axis CNC Press Brake GeniusPro (we call him Presley) has expanded our press brake bending capabilities, but smart Design for Manufacturability (DFM) still matters.
Let’s explore exactly what to consider when your parts require bending, and how our team at Accurate can help ensure your parts are formed efficiently.
Limitations to Understand for Better Manufacturability
1. On Large Parts, Check Clearance With Your Manufacturer
We recently added a 13-foot press brake to our fleet of equipment, but that doesn’t mean every 13-foot part can be bent without limitations.
Press brakes have uprights inside the working area, affecting what can physically fit during forming. That’s why clearance matters. So, if you’re designing a large part or a part with long flanges, we suggest checking with your manufacturer to see what’s possible. Collaborating early can prevent costly redesigns.
When partnering with our CNC machine shop, we can confirm whether your geometry works or if an adjustment is necessary for efficient bending.
2. Use as Few Bends as Possible
Before placing your order, review your design and determine if any bends can be removed. An additional bend may require another setup, costing time and money.
If the design does require multiple bends and cannot be simplified, don’t worry. We have a solution for your complicated parts. Splitting one complex part into two simpler components and welding them together afterward allows for easy bending and is often more cost-effective.
3. Avoid Placing Features Near the Bend
A common DFM challenge is placing features near a bend line. Material can get stretched during forming, and when bolt holes are too close to a bend, they can become deformed, and the bolt may no longer fit.
When your design cannot be adjusted to move the features away from the bend, we have a simple workaround: we suggest using slots instead of round holes. Slots perpendicular to the bend line are a better option because this gives the metal room to move during forming, enabling bolts to fit properly.
Small design adjustments like this save time, money, and production headaches.
DFM Adjustments for Efficient Parts
When it comes to forming complex parts, there is a difference between what is possible and what is practical, or what makes sense financially.
Extremely large parts or highly complex parts with many bends require custom tooling. But this is not always cost-effective, especially for low-volume projects.
Cost savings typically come from high-volume orders, so if it’s a long-term project with large quantities, then the tooling investment will probably make sense. In those cases, we can roll tooling costs into the part price.
But if you only need one or two parts, we can collaborate to adjust the part design, ensuring it is cost-effective while maintaining quality. Our precision CNC machining services ensure that even low-volume orders are produced efficiently.
Designing for Success
At our precision machine shop, we make bending simple. We’re ready to collaborate to solve any challenges involved with press brake forming.
To discuss the most efficient way to design your parts for fabrication, reach out to Accurate CNC or request a quote today.