Sheet Metal Forming

BRACKETS, COVERS, ENCLOSURES AND MORE

SHEET METAL FORMING

Staub Manufacturing Solutions is the preferred fabrication supplier of top OEMs. An ISO 9001:2015 certified company with over 20 years of experience, Staub has comprehensive sheet metal forming capabilities and is known for delivering exceptional results.

Our highly skilled operators utilize CNC press brakes with independent, programmable 6-axis backgauges, auto crowning, and adaptive bending technology to ensure the accuracy of every formed feature.

We form (or bend) sheet metal parts up to 120” in length (at 190 tons) out of aluminum, stainless steel, and carbon steel. We have a vast library of standard bend tooling and can accommodate most special forming requirements through low-cost custom tooling*.

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WHAT IS PRESS BRAKE BENDING?

Press brake bending is a common forming process for precision sheet metal fabrication. It forms predetermined linear bends in the laser-cut workpiece by squeezing (or pressing) it between a punch and die.

Before pressing, the blank is situated against two stops, called backgauges, which precisely stage the part for the form. During the pressing operation, the punch pushes the metal down into the die (typically v-shaped) to a preset position. The punch then retracts, releasing the part which retains its formed shape.

The most common type of press brake forming is air bending, where the punch and die never bottom out against the sheet material. The material only touches the tooling at three points: the punch tip and the die shoulders. This method can produce a large range of bend angles from one set of tooling and allows the parts to be over-formed as needed to accommodate for material spring back. Bottom bending, where the material contacts the punch tip and the die sidewalls, requires more tonnage than air bending and is used for special applications such as offset (Z-bend) forms.

While press brake bending has been around for a long time, its accuracy and efficiency have been greatly improved by modern technology. At Staub, before production, we take a 3D CAD model of the part and run it through bend simulation software to determine the best tooling solution as well as to look for possible forming issues. The press brake machine is then programmed off-line, and a detailed process plan is created for the operator.

At the machine, the operator is aided by a touch screen display, which gives them a 3D visualization of the various forming steps as well as a control for making precise adjustments. Our advanced press brake equipment provides additional features such as integrated CNC Crowning, which helps maintain consistent angles over long forms, and Automatically Controlled Bending, which monitors and adjusts formed angles with the help of in-tooling sensors.

CHOOSING SHEET METAL FORMING

Press brake bending is a very cost-effective way to produce formed sheet metal components due to its use of common tooling for a large variety of bend angles, form configurations, and material types. It is the preferred forming process for the production of up to 25,000 parts per year (beyond that, stamping may be the best solution).

Staub Manufacturing Solutions produces high-quality, formed sheet metal brackets, covers, enclosures, supports, panels, boxes, and more. Contact us today with your forming application.

*Through the use of special tooling, we can produce custom formed features such as hems, curls, louvers, bosses, sumps, and extrusions.

SUPPLYING QUALITY OEM’S WITH…

Brackets
Mounts
Enclosures

Covers
Panels
Frames

Displays
Stands
Carts

Boxes
Weldments
Assemblies

Talk to us today about your production fabrication needs.

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FABRICATION FAQ’S

Does Staub do prototype fabrication work?

We do everything we can to help our OEM customers bring their products to market. So, on
parts or assemblies that have future production demand, we work with them from the initial test
build, through the required PPAP run and on up to full production. As a general rule, though, we
don’t do stand-alone prototyping. We’ve found that non-production-oriented shops do a better
job with that type of work. If you’d like us to take a look at your specific requirement, please
Contact Us.

What is a typical turnaround time for a fabrication project?

Each project is different. Factors that affect the length of a production launch include, raw
material availability, special tooling or fixturing requirements, the complexity of the fabrication,
and our current production workload. We’ll give your work the attention it deserves to ensure
that it is successful right out of the gate. Talk to our sales team today to have them evaluate
your project.

What materials do you work with?

We fabricate components and assemblies from carbon steel, aluminum and stainless, including
most of varieties within those three groups of metals. If you have a special material application,
contact us to see if we can help.

What size fabrications suit you best?

We consider ourselves a light-gauge metal fabricator. That means that most components we
work with are made from ¼” thick metal (or thinner) and weigh less than 75 lbs. We do
manufacture complex welded assemblies up to about 500 lbs.

Do you offer engineering or design support?

Yes and no. Our engineering staff supports our customers with feedback on manufacturability
and suggestions for cost reduction. We don’t, however, offer full product design. Contact us
today to see if we can help.

What are your standard fabrication tolerances?

While every application is unique, depending on the material, size, how many bends and such,
we have created a basic guide for laser cut and formed parts that you might find helpful. You
can download that [here]. For specific information on your project, you’ll want to talk to our
sales team.#

What information do you need to be able to quote my fabrication project?

Providing complete project information is the best way to get a rapid quote turnaround and the
best pricing. Here’s what you’ll need to send in:
○ PDF Drawings (With notes/tolerances)
○ 3D CAD files (SolidWorks or STP format)
○ Quantities (Per Release and EAU)
○ Finish Requirements (Plating or Powder-coating specifications)

○ Weld Specifications (Including any required certifications)
○ Packaging Requirements (if needing other than bulk packing)

How do I know if my project quantities are a good fit for your operation?

Great question! Our specialty is ongoing, production fabrication, so we definitely shy away from
low-volume, one-time projects. Beyond that, it’s a little harder to pin down. I can say that
typically, on simple plates or brackets, we often run 5,000 or more parts per year and on more
complex fabrications, we typically run several hundred or more a year. The best way to
determine if your fabrication requirement is a good fit for us is to connect with a member of our
sales team.

What type of welding do you do?

We provide MIG, TIG, Spot and Projection welding in Steel, Stainless and Aluminum.

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