This page lists TBC Metalworks’ tube bending and fabrication specifications in one place for engineers and buyers. If your part falls outside these ranges, send us the drawing anyway. We often have tooling or a workaround that isn’t listed here.
Size ranges by process
| Process | Material form | Range |
|---|---|---|
| Rotary draw bending | Round tube | 1/8″ to 3″ OD (CNC mandrel: 1/2″ to 3″) |
| Rotary draw bending | Pipe | 1/4″ to 2-1/2″ NPS |
| Rotary draw bending | Square and rectangle tube | 5/8″ to 2″ square; rectangles from 3/4″ x 1-1/2″ to 3″ x 1-1/2″ |
| Rod bending | Solid rod | 1/8″ to 2″ |
| Roll / profile bending | Tubing | 1/2″ to 4-1/2″ OD |
| Roll / profile bending | Pipe | 1/2″ to 4″ |
| Press bending | Pipe | 1-1/4″ to 4″ NPS |
| Roll / profile bending | Other profiles | Square, rectangle, channel, angle iron, solid rod |
| End forming / swaging | Round tube | 1″ to 4″ OD |
| Beading | Round tube | Up to 0.065″ wall |
Centerline radius (CLR) tooling
Radii are centerline radius (CLR) unless noted. This is a general list and may not include all of our dies, so contact us for the latest.
Round tube
| Tube OD | Bend radii dies |
|---|---|
| 1/8″ | 0.5625″ |
| 3/16″ | 0.5625″ |
| 1/4″ | 0.5625″, 0.625″ |
| 3/8″ | 0.625″, 1.125″, 2.1875″ |
| 1/2″ | 0.75″, 1.25″, 1.5″ |
| 5/8″ | 1.25″, 1.5″, 2″, 3.5″ |
| 3/4″ | 1.35″, 1.5″, 1.875″, 1.9375″, 2″, 2.12″, 2.5″, 3″, 3.375″, 6.5″ |
| 0.78″ | 6.5″ |
| 22 mm (0.866″) | 76 mm (2.992″), 3.06″ |
| 7/8″ | 2″, 2.5″, 3″ |
| 1″ | 1.5″, 2″, 2.5″, 3″, 3.438″, 3.5″, 3.78″, 4.5″, 5.09″, 6.53″, 7″ |
| 1-1/8″ | 2.375″ |
| 1-1/4″ | 2″, 2.25″, 2.375″, 2.5″, 3″, 3.125″, 3.5″, 4″, 4.5″, 5″, 6″ |
| 1-1/2″ | 1.5″, 2″, 3″, 4″, 4.25″, 4.5″, 5″, 6″ |
| 1-5/8″ | 4″ |
| 1-3/4″ | 3″, 4″, 5.25″ |
| 2″ | 2″, 2.75″, 3.81″, 4″, 5.5″, 6″, 8″, 12″ |
| 2-1/2″ | 5″ |
| 3″ | 7″, 9″ |
Pipe
| Pipe size (NPS) | Pipe OD | Bend radii dies |
|---|---|---|
| 1/4″ | 0.54″ | 1.5″ |
| 3/8″ | 0.675″ | 2.5″, 3.5″ |
| 1/2″ | 0.84″ | 1.5″, 2″, 3″ |
| 3/4″ | 1.05″ | 2″, 2.5″, 3″, 3.75″, 4.25″, 5.5″ |
| 1″ | 1.315″ | 1.5″, 2″, 3″, 4″, 5″, 7″ |
| 1-1/4″ | 1.66″ | 2.5″, 2.83″, 3″, 3.9″, 4″, 5″, 5.75″ |
| 1-1/2″ | 1.9″ | 3.75″, 3.9″, 6″, 6.75″ |
| 2″ | 2.375″ | 3″, 5.118″, 6″, 7″, 7.87″, 8.375″, 8.69″, 9″, 10″, 12″ |
| 2-1/2″ | 2.875″ | 3.75″, 6″, 6.875″, 10″ |
Square and rectangle tube
| Profile | Bend radii dies |
|---|---|
| 5/8″ square | 8″ |
| 1″ square | 2.5″, 4.5″, 4.625″, 6.5″ |
| 1-1/4″ square | 3.125″, 3.625″, 4.625″ |
| 1-1/2″ square | 3.75″, 3.95″, 4″, 5″, 6.15″ |
| 2″ square | 4.5″, 7″ |
| 3/4″ x 1-1/2″ rectangle | 6.625″ |
| 1″ x 1-1/2″ rectangle | 3.54″ IR |
| 1″ x 2″ rectangle | 3.5″, 4.5″, 6″ |
| 1-1/4″ x 2″ rectangle | 2.75″ IR |
| 1-1/2″ x 2″ rectangle | 2.95″ IR |
| 1-1/2″ x 2-1/2″ rectangle | 3.75″ |
| 2″ x 1″ rectangle | 4″ |
| 2-1/2″ x 1-1/2″ rectangle | 2″ IR, 5″ IR |
| 3″ x 1-1/2″ rectangle | 8.875″ |
Rectangle radii marked IR are inside radius; all other radii are centerline radius (CLR). Tell us the bend direction (easy way or hard way) on rectangle parts and we will confirm which die fits.
Press bending (pipe)
| Pipe size (NPS) | Press bending radius |
|---|---|
| 1-1/4″ | 7.25″ |
| 1-1/2″ | 8.5″ |
| 2″ | 9.5″ |
| 3″ | 13″ |
| 3-1/2″ | 10.5″, 15″ |
| 4″ | 20″ |
Roll bending
| Rolling machine | Pipe (NPS) | Tube OD |
|---|---|---|
| Small rolling machine | 3/4″ to 2″ | 3/4″ to 2-1/4″ |
| CNC rolling machine | 1-1/4″ to 1-1/2″ | 2″ |
| Large rolling machine | 2-1/2″ to 4″ | 2-1/2″ to 4-1/2″ |
Roll bending is generally used for radii larger than about 15″.
Solid rod
Solid rod from 1/4″ to 3/4″, round and square, is also bent on a bending plate. For solid rod we work to inside radius.
Secondary operations
MIG and TIG welding, stainless and aluminum polishing, coping and notching, threading and tapping, CNC machining of holes and slots, CNC bandsaw cutting, and end forming (expanding, reducing, flaring, beading, ball forming, flattening). Laser cut plates, powder coating and anodizing are available through local partners.
Volumes, lead time and quoting
- Prototype through production; programs of 50 to 10,000+ units per year
- Minimum order: generally about 10 pieces
- Lead time: as little as one week
- Quote turnaround: within one business day
- Files we accept: PDF drawings, STEP and other 3D models
Company
TBC Metalworks · 1011 Ashwaubenon St., Green Bay, Wisconsin 54304 · 920-523-3020 · sales@tbcmetalworks.com · Founded 1987 · Ships across the United States