1. Ignoring Minimum Bend Radius

The mistake: Designers specify bend radii that are too tight for the chosen aluminium alloy and profile geometry. This can cause cracking, wrinkling, or deformation.

How to avoid it:

• Always check the minimum recommended bend radius for the alloy and temper you're using.

• For extrusion profiles, internal stresses make the material more sensitive—so stay on the safe side.

💡 Pro tip: MetaBend can help you calculate safe bend radii and suggest adjustments before tooling is made.

2. Overlooking Alloy Selection

The mistake: Using alloys that are hard to bend, such as 7075, without considering annealing or alternative materials.

How to avoid it:

• Choose bend-friendly alloys, such as 6060, 6063, or 5083, for most forming applications.

• If using harder alloys, allow for heat treatment or design adjustments.

3. Inconsistent Wall Thickness

The mistake: Extrusions with variable wall thickness often result in uneven bending, distortion, or collapsing.

How to avoid it:

• Keep wall thickness consistent across the bend section.

• If variations are necessary, consult with a bending specialist early in the design phase.

4. Tight Tolerances in the Wrong Places

The mistake: Applying unnecessarily tight tolerances in areas where bending naturally introduces variation—driving up cost or causing rework.

How to avoid it:

• Allow for relaxed tolerances in bend zones unless critical.

• Focus precision where it matters—e.g., mating surfaces, hole alignment, etc.

5. Lack of Pre-Bending Planning

The mistake: Ordering extrusions or cutting materials without considering how the profile will behave during bending.

How to avoid it:

• Plan cut lengths, orientation, and support features for bending ahead of time.

• Early collaboration with MetaBend can save time and material waste.

6. Missing Tooling Considerations

The mistake: Expecting “one-size-fits-all” tooling to deliver perfect bends on complex profiles.

How to avoid it:

• Understand that each project may require custom tooling for best results.

• Reusing old tooling can lead to inconsistent results if the profile or radius changes.

7. Not Accounting for Springback

The mistake: Aluminium tends to return slightly toward its original shape after bending—known as springback.

How to avoid it:

• Factor in springback compensation during tool design and CNC programming.

• MetaBend calculates and adjusts for this automatically in the forming process.

8. Poor Communication Between Designers and Benders

The mistake: Designers hand off drawings without discussing bending direction, orientation, or critical dimensions with the supplier.

How to avoid it:

• Share 3D models, detailed drawings, and clear notes early.

• When in doubt, talk to your bending partner (that’s us!).

Conclusion: Precision Starts with Planning

Avoiding these common mistakes can save time, money, and frustration—and ensure a better final product. At MetaBend, we don’t just bend parts—we collaborate with you to make sure everything is right from day one.

Ready to start a new project or review an existing one?
Contact MetaBend for expert guidance on aluminium extrusion bending that works—first time, every time.