EPTAHUB Provides High-Precision Tube Bending Solutions For Round Metal Tube Stock, Tailored To Fulfill Your Specific Requirements
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Tube bending is a collection of manufacturing procedures that modify the form of a pipe or tube, crafting the desired geometry or features to meet particular needs. During the process, tube stock is loaded into a bending machine, which employs mechanical force to push the tube against dies and rollers, forcing the tube to take on the intended shape. Tubes can be bent in two dimensions, where the openings stay on the same plane, or in three dimensions, where they lie on different planes. CNC tube bending allows for multiple bends, minimizing the necessity of welding or assembling complex shapes using elbow and straight tube segments.
EPTAHUB offers a comprehensive range of custom tube bending services for your applications, featuring instant online quoting, Design for Manufacturability (DFM) support, and competitive lead times. Whether you require standard rotary draw tube bending or highly precise mandrel tube bending, EPTAHUB delivers various processes to meet your tube fabrication needs, regardless of whether you need low or high production volumes. Additionally, EPTAHUB provides laser tube cutting services for parts that require cut features such as holes, slots, and more. The material options for our tube bending services include stainless steel, aluminum, and alloy steel.
Our tube bending service is developed based on common industry standards to guarantee a seamless manufacturing experience. EPTAHUB can achieve stricter tolerances following a manual review by one of our project engineers. Below is a list of the standards and tolerances specific to our drawn or mandrel bending techniques for round profiles:
EPTAHUB's tube bending services are designed to create custom round tubes in a variety of shapes and materials:
These materials offer resistance to rust and corrosion, making them perfect for outdoor, wet, or salty environments. 316 provides slightly superior corrosion resistance compared to 304.
This is a rigid, lightweight tube that does not rust. It is widely used in lightweight frames and aircraft components.
This is an extremely strong and durable tube, commonly used in race cars and aerospace structures. The seamless design reduces potential failure points, making it ideal for critical applications.
This is a popular choice for general-purpose use. DOM tubes are smooth and strong, suitable for car parts; HREW tubes are more cost-effective and well-suited for simple structures; CREW tubes are cold-formed, offering enhanced strength and a better finish.
The table below shows the range of tube sizes available for these services. For more details, visit our standard tube sizes resource page.
| Material | Minimum O.D. | Maximum O.D. | Minimum wall thickness | Maximum wall thickness |
|---|---|---|---|---|
| Stainless Steel 304 | .250" | 2.000" | .035" | .188" |
| Stainless Steel 316 | .250" | 2.000" | .035" | .120" |
| Aluminum 6061 | .250" | 2.000" | .035" | .188" |
| Steel 4130 (Chromoly) | .375" | 2.000" | .035" | .188" |
| Steel A513 Type 5, DOM | .250" | 2.000" | .035" | .188" |
| Steel A513 Type 1, HREW | 1.000" | 2.000" | .065" | .120" |
| Steel A513 Type 2, CREW | .500" | 2.000" | .035" | .065" |
When it comes to tube bending, there are several steps you can take during the part design phase to ensure a smoother quoting and manufacturing process. We have compiled a few tube bending Design for Manufacturability (DFM) tips below. For more tips, check out our top tube bending design tips article.
In addition to the bend distance guidelines, EPTAHUB has found that the following tube diameter (OD) to center line radius (CLR) combinations are more widely available across our extensive network.
Note: CLRs smaller than 2 times the OD carry a higher risk of manufacturing issues, especially when combined with thinner wall thicknesses. We recommend using CLRs larger than 2 times the tube OD for your projects.
The list below presents tube OD values (in decimals or fractions) along with their corresponding CLRs to assist you in designing your project. It is recommended that a single tube uses only one CLR to simplify manufacturability.
.188″ (3/16″) OD: CLR of .25″, .5″, .75″, 1″, 3.5″, or 4″
.25″ (1/4″) OD: CLR of .25″, .5″, .75″, 1″, or 1.25″
.375″ (3/8″) OD: CLR of .75″, 1″, 1.25″, 1.5″, 2″, or 3″
.5″ (1/2″) OD: CLR of .75″, 1″, 1.25″, 1.5″, 1.75″, 2″, 2.5″, 3″, or 3.5″
.625″ (5/8″) OD: CLR of 1″, 1.25″, 1.5″, 1.75″, 2″, 2.5″, 3.5″, or 4″
CLR of .75″, 1″, 1.25″, 1.5″, 1.75″, 2″, 3″, 3.5″, or 4″
.875″ (7/8″) OD: CLR of 1.5″, 2″, or 2.5″
1″ OD: CLR of 1″, 1.5″, 2″, 2.5″, 3″, 3.5″, or 4″
1.25″ (1 1/4″) OD: CLR of 1.25″, 1.5″, 2″, 2.5″, 3″, 3.5″, or 4″
1.5″ (1 1/2″) OD: CLR of 1.5″, 1.75″, 2″, 2.5″, or 3″
1.75″ (1 3/4″) OD: CLR of 2.5″, 3″, 3.5″, or 4″
2″ OD: CLR of 2″, 2.5″, 3″, or 4″
EPTAHUB provides a complete range of tube bending and pipe bending capabilities. These services include:
This method (also referred to as mandrel bending) is similar to rotary draw bending; however, it fully preserves the internal tube profile throughout the bending process. This is achieved by using an internal support called a mandrel, which maintains the tube's structure during bending, ensuring minimal to no unwanted deformation. The mandrel tube bender features a long bed with a mandrel rod, which holds the mandrel precisely at the tangent point of the bend. The tube slides over the mandrel, the machine clamps down on it, and the tube is bent while the mandrel remains stationary. Mandrel tube bending is particularly useful for tubes with thin wall thicknesses, large diameters, and tight radii, where collapsing during bending is a common concern.
By far the most widely used method, rotary draw benders utilize a clamping die, radius (or bend) die, and pressure die to hold the tube in place throughout the entire bending process. The tube is clamped to the bend die and is "drawn" around the other dies using hydraulic or electrical power, resulting in highly accurate and repeatable bends. Rotary draw tube bending processes can be manual, semi-manual, or CNC-operated. Computer-guided rotary draw bending offers unparalleled precision, especially for high-volume applications. However, the setup time can be longer, and each unique bend requires custom tooling to be created.
In roll tube bending (also known as roll bending), three dies (or rollers) are used to secure the tube. A piston applies pressure to the tube, and the operator "rolls" the pipe through the machine, creating a gradual bend (also called an arc). The tube is repositioned in the dies, the piston is lowered further, and the process is repeated until the desired profile is achieved. This method is often manually operated, but it can also be motorized for additional power. Roll tube bending allows for variable bends and angles without the need for additional tooling, making it ideal for large, gradual bends. However, its accuracy and repeatability are limited.
With compression bending, the tube or pipe is clamped in position, and direct force is applied to create the bend. This process is mainly used for single-bend applications. No internal support is used in compression bending, which typically results in an oval cross-section and may cause crushing at the bend. Bends are generally limited to angles of 120 degrees or less.
Tube bending can be applied across a wide range of industries. From architectural and lighting fixtures in buildings to vehicle exhaust systems, the applications are diverse. Below is a list of some of the notable sectors where our tube fabrication and bending services are an excellent fit:
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We hold ISO 9001:2015, ISO 13485, IATF 16949:2016, and AS9100D certifications.
Our team of Solutions Engineers and Process Specialists is available to support you and provide answers to all your fabrication and manufacturability questions.
Learn how to easily obtain an instant quote for Tube Bending services through the EPTAHUB Instant Quoting Engine®.
To fully meet your comprehensive manufacturing needs, EPTAHUB offers a variety of complementary services that pair seamlessly with our tube bending solutions. These related services are designed to streamline your production workflow, enhance part quality, and ensure that every aspect of your project meets the highest standards.
Beyond bending, we provide precise laser tube cutting services to create intricate features like holes, slots, notches, and custom cutouts. This service ensures tight tolerances and clean edges, eliminating the need for secondary cutting operations and simplifying the integration of bent tubes into your assemblies.
For projects requiring joined tube components, our professional welding services deliver strong, reliable bonds. We handle various welding techniques suitable for different materials—including stainless steel, aluminum, and alloy steel—ensuring structural integrity for applications ranging from automotive to aerospace.
Our end-to-end tube fabrication services cover more than just bending and cutting. We offer deburring, chamfering, threading, and surface finishing (such as powder coating or anodizing) to prepare your tubes for immediate use. This one-stop approach reduces lead times and minimizes the need to coordinate with multiple suppliers.
When your bent tubes require precision machining for fittings, flanges, or other mating components, our custom machining services come into play. We utilize advanced CNC machining equipment to produce parts that align perfectly with your bent tubes, ensuring seamless assembly and optimal performance.
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