Metal folding

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Overview
Sheet metal folding is a bending process that converts flat metal sheets into three-dimensional parts used for housings, enclosures, frames, cabinets, trays and chassis. The process is suitable for series production and can be adapted to a wide variety of part geometries and materials.

Capabilities

• Bending force range: 50 to 400 tonnes.
• Maximum part length: up to 4 metres.
• Robotic folding available for serial production to increase throughput and consistency.
• Materials routinely processed: carbon steel, stainless steel, corten and aluminium.
• Equipment: CNC press brakes and robotic press brakes for automated folding sequences.

How the process works
Selection of appropriate material and thickness; cutting to the flat pattern; programming and loading into CNC bending presses or robotic folders; using dedicated tools and dies to control bend radii and angles; validation of first pieces and periodic in-process checks to ensure dimensional stability and repeatability.

Applications / Typical sectors
Teklan provides folding solutions across multiple sectors. Typical applications include:

• Elevators: cabins, doors, panels and structural components.
• Railway: carriage panels, roofs, doors and structural parts.
• Machine tools: frames, housings and heavy machinery components.
• Industrial refrigeration: panels for cold rooms and ventilation systems.
• Industrial storage: shelving, crates and storage structures.
• Metal furniture: cabinets, tables and related items.
• Renewable energy: components for solar and wind systems.

Advantages

• High precision and consistent quality: controlled folds and tight tolerances for complex geometries.
• Design flexibility: wide range of shapes, angles and fold configurations.
• Cost efficiency for long runs: optimized material use and automation lower cost per part.
• Fast cycle times suitable for mass production.
• Added stiffness: folds increase part rigidity and can reduce need for additional reinforcements.

Quality, repeatability and traceability
Processes are set up for series production with first-part approval, definition of critical dimensions, possible design of gauges/fixtures, periodic sampling, recording of inspection results and documentation linking each reference to drawing revision, CNC program and bending parameters to ensure repeatability and traceability by lot/date/material.

Design and production data to consider (for accurate industrial series planning)

• Dimensioned drawings (PDF) showing flange lengths, angles, radii and critical dimensions.
• Flat pattern files (clean DXF) for cutting and nesting.
• 3D files (STEP/IGES) when the part is part of an assembly to assess fit and interfaces.
• Quantities: batch sizes, estimated annual consumption and replenishment frequency to evaluate tooling/program optimisation.
• Quality requirements: critical tolerances, surface/appearance constraints, traceability and packaging/delivery specifications.

Integration of processes
Folding can be combined with upstream and downstream operations such as laser cutting, punching, stud insertion, welding and assembly to streamline flows, reduce handling and maintain consistent revision control across processes.

Characteristics / technical specifications

• Bending force: 50–400 tonnes
• Maximum usable bend length: up to 4 m
• Robotic folder: available for serial production
• Typical materials: carbon steel, stainless steel, corten, aluminium
• Key equipment: CNC press brakes and robotic press brakes
• Process controls: first-part approval, periodic sampling, gauges/fixtures, documented CNC programs and bending parameters
• Typical part types: housings, enclosures, frames, cabinets, trays, chassis, metal furniture