Forming is the process of shaping raw materials into desired shapes, forms, and structures. It involves manipulating the material through various techniques to achieve specific dimensions and configurations. Common forming methods include bending, rolling, forging, and stamping. Each technique serves a unique purpose in transforming materials, allowing manufacturers to create a wide range of products.

At TBSI, our parts are subjected to stringent quality control processes to meet the highest industry standards and specifications. Our dedicated team is also available to provide individual support and direction throughout the manufacturing process.

Pieces of metal that were formed using tube bending to become handrailsREQUEST A QUOTE

Panel Bending

Panel bending is a manufacturing process that shapes metal sheets into desired forms. It involves applying force to deform the material over a curved surface or a predetermined bend line. This is extensively used in automotive, aerospace, and construction industries to create components like body panels or structural sections.

Advantages of Panel Bending

The key advantages of panel bending include the following:

  • Precise and consistent: Advanced CNC panel benders ensure that each bend is accurate, meeting tight tolerances required in various industries.
  • Versatile material handling: The bending process is adaptable to multiple materials, including metals like aluminum, steel, and stainless steel.
  • Efficient production workflow: CNC systems and robotic technology streamline workflows, reducing manual labor and production time. This efficiency enhances productivity.
  • Complex shape capabilities: Panel bending allows for the creation of complex shapes and forms, expanding design possibilities in various industries.
  • Reduced waste and costs: Precision panel bending minimizes material waste, contributing to cost savings. It also ensures that each sheet is utilized efficiently.

Tube Bending

Tube bending is a process that permanently bends straight tubes into the desired shape. These bent tubes are used in systems to alter the direction of fluid flow. Some factors that influence the process and component’s quality include the material and the tooling used. Other aspects to consider include the amount of pressure applied, the type and amount of lubrication employed, and the bending geometry.

Some products commonly made using tube bending include air conditioning system components, automotive parts, furniture frames, handles, instruments, and stair railings.

Types of Tube Bending

The following are various tube bending methods, each tailored to specific project requirements:

  • Form-bound is where the tube’s final form depends on the die used. It includes press bending and rotary draw bending.
  • Freeform refers to processes in which the tube’s final form depends on its movement through the die. These processes include roll bending.
  • Cold tube bending involves processes that occur at room temperature, including press bending, rotary draw bending, compression bending, roll bending, and bending springs.
  • Hot tube bending techniques utilize heat to improve the tube’s plastic deformation characteristics during operations.

CNC Forming

CNC brake presses are used in CNC forming processes to bend sheet metal and other materials. These machines are equipped with a punch and die set. The machine forces the material onto the die when the workpiece is put between the two components. As a result, the piece takes on the shape of the die. This is a widely utilized technique in various industries such as manufacturing, automotive, and construction.

Examples of products that are commonly made using CNC forming include:

  • Brackets
  • Cabinets and enclosures
  • Conveyor system parts
  • Material handling system components
  • Store fixtures
  • Tubular frames

CNC Roll Forming

CNC roll forming is a highly sophisticated manufacturing process that utilizes CNC technology to bend continuous metal strips into specific shapes. This advanced method is widely employed to produce long components with a consistent and precisely engineered form. It relies on sets of rolls mounted on consecutive stands. Each set incrementally creates small bends in the workpiece.

Wire Forming

Wire forming is a manufacturing process focused on reshaping a coiled wire by applying force to achieve a contour. The process starts with straightening the coiled wire before undergoing transformations to attain the desired shape. Examples of wire forming methods include bending, swaging, piercing, chamfering, and shearing.

Products commonly made using wire forming include clamps, clips, hooks, pins, springs, wire baskets, wire displays, wire guards, and wire screens.


An infographic explaining TBSI's forming processes

Choose TBSI for Your Next Forming Project

At TBSI, we deliver high-quality steel components and fabrications that surpass your expectations! We provide customers with solutions that meet their specifications with competitive pricing and quick lead times. Whether you need tube bending, CNC forming, rolling, or wire forming assistance, we’ve got you covered. We also provide various cutting and machining services.

Contact us to learn more about our services, or request a quote to get started!