The Hidden Challenges of Bending Aluminium Extrusions

Aluminium is often chosen for its light weight, strength-to-weight ratio, and corrosion resistance. From transport and construction to energy and design, it’s the go-to material when efficiency and performance matter. But when it comes to bending aluminium extrusions, things get more complicated than most expect.

At MetaBend, we’ve seen firsthand that the challenge isn’t just about shaping metal — it’s about preserving function, precision, and appearance.

1. Springback – Aluminium’s Natural Resistance

One of the biggest hurdles in bending aluminium is springback. After bending, the profile tends to “spring” back toward its original shape.

• Alloys like 6061 and 6082, known for their strength, often show more springback.

• Softer alloys like 6060 or 6063 are easier to bend but still require careful control.

Solution: Predicting springback comes from experience and data. At MetaBend, we adjust bending parameters and tooling to achieve the correct final geometry.

2. Profile Distortion – Keeping Shapes Intact

Extrusions are often designed with thin walls, sharp corners, or complex hollow sections. These features can lead to:

• Wrinkling on the inside radius.

• Cracking on the outside radius.

• Twisting in asymmetrical profiles.

Solution: Using the right bending technique (roll bending, stretch forming, or pushing methods) helps reduce distortion. For critical projects, we work closely with designers to adapt the profile or set realistic tolerances.

3. Surface Finish – More Than Just Looks

Many aluminium extrusions are visible in the final product, meaning scratches, dents, or marks are unacceptable. The bending process, if not handled correctly, can easily damage anodised or powder-coated surfaces.

Solution: Protective tooling, smooth handling, and post-bending finishing options ensure that both function and aesthetics are preserved.

4. Alloy and Temper Selection – Not All Aluminium is Equal

The choice of alloy and heat treatment condition (temper) has a huge impact on bendability. For example:

• T4 tempers are more formable but may need heat treatment afterwards.

• T6 tempers are stronger but much harder to bend without cracking.

Solution: We always evaluate the alloy/temper combination before bending and can suggest alternatives if the design allows.

5. Precision and Tolerances – Getting It Right Every Time

Even small deviations in radius or straightness can affect assembly. In industries like transport or construction, a few millimetres can mean the difference between a perfect fit and costly rework.

Solution: CNC-controlled machines and years of operator expertise allow us to achieve repeatable results, even with challenging geometries.

Why Experience Matters

On paper, bending aluminium extrusions might seem straightforward. In reality, it’s a balance of material science, engineering, and craftsmanship. Mistakes cost time, money, and material. Experience ensures those mistakes don’t happen.

At MetaBend, we specialise in solving these hidden challenges — so our customers receive not just bent profiles, but reliable solutions for their projects.

👉 Looking for support with your aluminium extrusion bending project? Contact us and we’ll be happy to help.