Aluminium thickness alone does not establish whether a bend will form successfully. Alloy and temper influence formability, while tooling and handling affect the visible finish. Confirm these details before selecting a machine or promising a minimum radius.
Identify alloy and temper
State the complete material specification, thickness and condition. Do not apply one minimum-radius rule to all 5000- or 6000-series aluminium. Use material-supplier data and an application trial for the actual alloy and temper.
Include rolling direction where relevant. The required orientation of a bend and the available flat pattern may influence the practical forming route.
Check radius and flange together
Tool selection affects force, radius and minimum supported flange. Enlarging the die opening may ease some forming conditions but can change the component geometry. A small-radius drawing may need revision or another forming approach if the material cannot support it.
Ask the supplier to assess the punch, die and forming method together. Avoid using a generic tonnage table as a formability guarantee.
Define acceptable marking
Identify visible faces, protective film and finish requirements. Clean tools, appropriate die shoulders and compatible protective solutions can help, but their suitability depends on the load and component. Trial the surface rather than describing any machine as universally mark-free.
Consider burrs, contamination, stacking and turning between bends. These can damage cosmetic surfaces even when the tooling itself is suitable.
Prove a complete component
Test the intended alloy, temper and thickness with the proposed tools. Inspect the bend and finish using the agreed method and check the assembled fit. For structural or critical components, agree inspection requirements with the responsible engineering team.
Selecting a PBXS configuration
Selmach’s premium Morgan Rushworth PBXS range can be assessed alongside suitable hydraulic, hybrid or electric alternatives for your aluminium work. Capacity, gauging, tooling, control and handling should reflect the whole production mix.
Provide material certification details where available, drawings, required radii, maximum bend length, tolerances and batch sizes. Include your most demanding cosmetic panel and bracket. Ask Selmach for a tested configuration and an itemised quotation.
Use our tooling guide for the package detail and our accuracy guide to structure the comparison. Do not translate axis-positioning figures into an unsupported finished-part tolerance.
Published 21st October 2026