Bending Wall Thickness Capacity Chart
Rogue Fabrication we work hard to provide our customers with the most complete and accurate tube bending information available. We do out part to ensure that your fab shop runs as smoothly as possible. Although the chart below is the result of tests we performed on purchased materials, we cannot guarantee that you will achieve the same results due to the wide variation in material quality from one mill to another. If you want to know what to expect from a specific material, we offer bending diagnostic services. If your tubing bender does not perform to the limits shown in this chart, please call so we can help diagnose the problem. The culprit is usually setup, material quality, or lubrication. The solutions to these issues are usually easy.
NOTE – With the recent release of our affordable and high-performance mandrel conversion, we have not yet tested all dies to the limit in terms of minimum wall thickness. We will continue to do testing and add the new dies we’re designing for the machine as we discover new lower limits to minimum bend radii. Please e mail us with your questions!
Please select HD or xHD machine capacity for compatibility with the mandrel attachment
Definitions / Notes
Center line radius. See M600 Bender Tech for more info.
We test primarily 6061-T6 because if that will bend, most other aluminum alloys will bend fine. Please see critical notes below on aluminum.
We test 1020 DOM and 4130N DOM primarily. We have found that good quality HREW bends the same, but there are many more alloys/grades of HREW, so it can be a source of inconsistency.
We only test low carbon 304, 304L. In our experience, 316 and 316L bend similarly to the 304 alloys, and 409 bends better than them (less prone to wrinkling). Please look up Ferrari F355 headers before selecting 409 stainless for header applications!
Standard Model 600 bender, no TWA (thin wall attachment).
M600 W/HD Kit
Model 600 HD, or a Standard M600 with HD kit ($65) added, and 2 pressure dies. See “HD Kit” in the dies section for more information.
Xtreme heavy duty Model 600 (thicker frame and pins).
Thin Wall Attachment
Drop in subframe that allows ultra fine tuning of bend characteristics. As of 10-5-2016 this option is not yet for sale on our web page. Call us to get on the waiting list. This IS 100% compatible with all current M600 machines.
Bolt on frame that allows a metal mandrel (plug) to be installed inside the tubing where the bend is taking place. This holds the tubing open during the bend and allows bending of thinner material with amazing bend quality. This is ideal for headers, some exhaust work, and of course beautiful structural work like roll cages.
Nominal Pipe Size – for more info on pipe and tube, see M600 Bender Tech.
Pipe schedule. This is how pipe thickness is specified. Search online and you will find a pipe schedule with decimal thicknesses listed.
To Be Determined. As a small company that is rapidly expanding our product offerings and innovating in affordable metalworking technology, we frequently offer products before we have the chance to find their limit in all material sizes. That is the case where you see “TBD” on a die listing.
Important Capacity Considerations
Bending the absolute minimum that is listed in the table above will produce the highest amount of deformation possible on any given die. Going up even one thickness (like from .095 to .120, or .083 to .095) will typically improve bend quality significantly.
Aluminum is typically produced and sold in T6 temper (higher numbers are stronger and more brittle, whereas lower numbers like T0 are weaker and more ductile). The high T6 temper is ideal for strength and works well for machining and can be welded okay. It is far from ideal for cold working (bending) as it is prone to cracking. Sometimes you can’t see these cracks. Purchasing your material in T0 temper or de-tempering it down to T0 is the best defense against cracking. The material can be re-tempered back to T6 after cold working/forming is done at a heat treatment shop. We have bent .125″ wall aluminum in 6061-T6 without visible cracks in every rated application on our table shown above. The .250″ wall applications are more likely to crack and more likely to require bending to be done on material in T0 temper state.
We ALWAYS recommend you buy your material from a reputable supplier with material certifications and buy a small amount to test before you order a truckload. If you shop around until you find a better deal than anyone else can get, you are probably buying junk material. Don’t commit to 100 sticks before you test it in a tubing bender! Also, if you want to be 100% certain that your exact material will bend nicely on a die, we are happy to test it for you before you purchase, you can order the test from our online store.
We offer 2 hydraulics systems for our machine. The air/hydraulic system covers the entire chart above. The electric/hydraulic system can be configured with a 5 ton or 9 ton cylinder, and the 5 ton maxes out at 1.5 x .156 wall square tube or 1.75 x .156 round tube, or 2.00 x .120 round tube. This is because the power of the electric/hydraulic system is biased more toward speed than outright tonnage on the 5 ton system. The larger 9 ton cylinder is slower but covers this whole capacity chart.
This page is NOT a substitute for machine operation instructions. You cannot tell from this capacity chart how to set up your specific model and revision of tubing bender to bend within these capacities. Your original instructions are the way to tell how to set up your machine and ensure you are being safe.
Do you have a Thin Wall Attachment?
We discontinued the Thin Wall Attachment in late 2019. We still have a chart that includes it’s performance. View that page here: TWA Chart