Tube Bending and Forming
Precision tube bending, end forming, and beading. Built on the Boyce Industries process now running along side AED, serving motorsports, aviation, aerospace, defense, and industrial fabrication.
Bending capabilities
Round and rectangular tube across the materials we stock:
- 4130 chromoly (from Webco)
- Docol R8 advanced high strength steel (from SSAB)
- Streamline and aero tube
- Stainless
- Aluminum, primarily 6061-T6
- Titanium (6AL-4V) on request
Standard bend angles of 30, 45, 60, 90, and 180 degrees, with custom angles to print. Standard angular tolerance is +/- 0.5 degrees.
CLR, radius, and tooling
Bends are called out to Center Line Radius (CLR), the industry standard for round tube (radius down the center of the tube, not ID or OD). Square and rectangular tubes reference Inside Radius.
Short radius and long radius options are designed so parts nest together, critical for tight chassis, cage, and header work.
Tight radius bends use the full tooling stack:
Full tool sets used:
- Bend die: the primary form the tube wraps around
- Clamp die: holds the tube end during the bend, with clamp length driving how close two bends can sit next to each other
- Pressure die: supports the unbent tube and loads it against the mandrel
- Mandrel: internal ball-and-body tool that prevents collapse on tight radii
- Wiper: sits between the bend die and the incoming tube for clean, wrinkle-free transitions
Our tooling list is published online. If your part calls for a size we do not stock, tell us early and we will scope it before quoting.
Rectangular tube: E-plane and H-plane
For rectangular tube, orientation matters and tooling changes with it:
- E-plane (easy plane): bending a 2 x 3 tube against the 3 inch side
- H-plane (hard plane): bending a 1 x 2 tube against the 1 inch side
Call out the plane on your print.
End forming and beading
- End forming: reshaping a tube end for slip-fit into a same or different sized tube
- Beading: a raised bead around the tube diameter that lets a hose or flexible line clamp in place
- Beaded ends produced via internal roll forming
- Flaring
How to order
Send a print with:
- Material grade, OD, and wall
- CLR
- Bend angles and orientation (E or H plane for rectangular)
- End conditions (cut length, deburr, form, bead)
- Quantity and delivery target
Ready to send a print?