TBC Metalworks roll bends tube, pipe and structural profiles into large-radius arcs, full circles, hoops and coils at our shop in Green Bay, Wisconsin. Roll bending, also called profile bending, is the process for sweeping bends that are too large for rotary draw tooling, which in our shop tops out at a 12″ centerline radius. We generally roll anything larger than about 15″.
How tube roll bending works
The tube passes through three rolls, usually in a pyramid or triangle layout. The top roll is adjusted down in steps while the tube is run back and forth, so the curve tightens gradually until it reaches the target radius. Because there’s no fixed bend die, one setup can produce many different radii, and the result is a smooth, continuous curve with no joints or fittings. We run both NC and CNC tube rolling machines.
Roll bending size range
| Material form | Size range |
|---|---|
| Tubing | 1/2″ to 4-1/2″ OD |
| Pipe | 1/2″ to 4″ |
| Profiles | Round tube, solid rod, square tube, rectangle tube, channel and angle iron |
Press bending large pipe
For larger pipe, we also press bend 1-1/4″ to 4″ NPS pipe on fixed-radius tooling:
| 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″ |
What we roll
- Large rectangle and round hoops, rolled and welded closed
- Large diameter helix coils
- Rolled stainless steel coils for heating and evaporator coil equipment
- Round circles and rings
- Bike racks, profile bent and welded
- Commercial outdoor applications and signs
- Square steel rolled tube
Materials
Carbon steel (A500, A513, A53, DOM, ERW), 304 and 316 stainless steel, 6061 and 6063 aluminum, and copper.
Rolling plus fabrication
Rolled parts often need to be closed into a ring, cut to an arc length, or attached to other parts. We weld (MIG and TIG), cut, drill, polish and coordinate powder coating, so you get one finished part from one supplier. Many parts also combine rolled sweeps with tight mandrel bends, and we can do both on the same part.
Volumes and lead time
We handle prototypes through production runs of 50 to 10,000+ units per year, and projects can ship in as little as one week.
Get a roll bending quote
Send your drawing (PDF), a STEP file if you have one, material, radius and arc length or chord, and annual volume through our quote form or to sales@tbcmetalworks.com. We’ll reply with a quote within one business day.