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Can a Profile Bending Machine Bend Multiple Radii in One Pass?

Profile bending machines are versatile tools used in various industries to shape and bend metal and other materials. One of the key questions often asked about these machines is whether they can bend multiple radii in a single pass. In this article, we will explore the capabilities and limitations of profile bending machines and discuss their ability to bend multiple radii efficiently and effectively. We will also present a list and a table that will enhance your understanding of this topic.

Understanding Profile Bending Machines

Multiple Radii Bending with 3D Freeform
Multiple Radii Bending
Single Radius Bending

Profile bending machines, also known as section bending machines, are widely employed in industries like construction, automotive, and manufacturing. They are essential for creating curved or bent components from steel or aluminum profiles. These machines use a set of rollers and dies to bend the material to the desired shape.

aluminum profile bending machine
PBA Aluminum Profile Bending Machine

Aluminum Bending Machine

Up to 15 Independent Controllable Servo Axes. Photoelectric positioning. CNC Automatic control. Accuracy is as high as ≤0.01mm.
Can be bent in various shapes (3-D graphics, C-shaped, U-shaped, full circle, ellipse, multiple radii combination shapes, etc.).
Suitable for difficult variable-curvature arc aluminum bending processing.

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section bending machine
PBH Profile Bending Machine

PBH Section Bending Machine

Up to 10 Drive Units; 3D Guide Rollers; High-Strength and Large-Torque Design(Can Bend S355 Structural Steel), Continuous High-Intensity Bending. PBH Section Bending Machine: Bend More Than 8 Types Section. Hard-Way or Easy-Way Bending for I Beams. Bent SUS and Iron Angle, Channel, Round/Square Bar, I Beam, Pipe, or Square/Rectangle Tubing.

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Multiple Radii Bending

Multiple radii bending is a specialized bending process that involves shaping a workpiece or profile into a design that features multiple curves or radii in a single pass. This process is commonly used in various industries, including construction, manufacturing, and automotive, where components with complex and aesthetically pleasing shapes are required. Achieving multiple radii bends in a single pass can be a challenging task, but it offers several advantages, such as improved efficiency, reduced production time, and enhanced product quality.

When it comes to bending multiple radii in one pass, it’s important to understand that profile bending machines vary in terms of their capabilities. Some machines are designed for simple, single-radius bends, while others can handle more complex tasks involving multiple radii. The ability to bend multiple radii in a single pass largely depends on the machine’s design, its roller configuration, and the material being processed.

Factors Affecting the Capability to Bend Multiple Radii in One Pass

  1. Machine Type: Different profile bending machines are built with varying degrees of versatility. Some are specifically designed for single-radius bending, while others are equipped to handle multiple radii.
  2. Roller Configuration: The arrangement of rollers on a profile bending machine significantly impacts its ability to bend multiple radii. Machines with adjustable rollers or multiple sets of rollers can accommodate various radii in one pass.
  3. Material Type: The material being bent plays a crucial role. Harder and thicker materials may require multiple passes or specialized tools to achieve multiple radii bends.
  4. Roller Diameter: The size of the rollers can affect the range of radii a machine can handle. Larger roller diameters are often better suited for bending multiple radii.
  5. Machine Capacity: The size and capacity of the profile bending machine can also determine its ability to handle multiple radii. Smaller machines may be limited in this regard.

Multiple Radii Bending With CNC PBA Aluminum Bending Machine

Multi-segment arc program recipe input steps

Under the “Main Interface”, press the “Multi-segment Program Recipe” key, and the system will enter the “Multi-segment Arc Program Editing” interface, as shown in the figure below:

Profile bending machine bends multiple radii

Note: The standard configuration of the PBA series CNC aluminum bending machine operating interface is in English, and other languages can be customized.

The operation steps of the multi-segment arc processing program are basically the same as the C-shaped operation steps. In the “Multi-segment arc formula”, enter the program name, the arc radius of each arc segment, the arc length of each segment, the head L1, the tail L2, the fixed wheel radius, Various parameters such as starting position, the total number of feeds, feed coefficient of each section, material retrieval delay, synchronization coefficient (default is 1), etc., press the “Save Recipe” key, the formula will be automatically saved, press the “Enter Processing” key to enter Multi-segment arc processing interface, in the “multi-segment arc processing” interface, press the “Start” key to enter the automatic processing program.

Note: Precautions for setting parameters in multi-segment arc formulas

The data content in the multi-segment arc formula is basically the same as that in the C-shaped formula, and the basis for setting the data is also the same. The differences are as follows:

  1. C-shaped processing can only bend arcs with one radius; multi-segment arc processing can process various variable curvature arcs composed of up to 24 different radii;
  2. For multi-segment arc formulas, the number of segments to be processed can be set as needed (the above figure sets 5 segments);
  3. Within the set number of segments, the total number of feeds can be set; when the total number of feeds is “1”, the number of feeds for each arc can be set (the number of feeds for each arc can only be odd number).

Profile Bending Machine Types and Their Multiple Radii Bending Capabilities

Machine TypeRoller ConfigurationMaterial TypeRoller DiameterMachine CapacityMultiple Radii Bending Capability
Standard BendersFixed rollers for single-radiusMild steelSmall to mediumLimitedLimited
Universal BendersAdjustable rollersSteel, aluminumMedium to largeModerateModerate
Pyramid BendersMultiple sets of rollersVarious metalsLargeHighHigh
Specialized MachinesCustomized roller configurationsExotic metalsLargeHighHigh

It’s clear from the table that different types of profile bending machines offer varying capabilities when it comes to bending multiple radii in one pass. While standard benders have limitations, universal and pyramid benders are more versatile and suitable for such tasks. Specialized machines can be tailored to handle unique requirements effectively.

The Benefits of Bending Multiple Radii in One Pass

Bending multiple radii in a single pass can offer several advantages, including:

  1. Time and Cost Efficiency: Using a machine capable of bending multiple radii in one pass reduces the need for multiple setups and passes, saving time and labor costs.
  2. Precision and Consistency: These machines can achieve precise and consistent bends, ensuring high-quality end products.
  3. Reduced Material Waste: Minimizing material waste is crucial in resource-conscious industries, and efficient profile bending helps in achieving this goal.


In conclusion, profile bending machines come in various types, each with its own set of capabilities regarding bending multiple radii in one pass. It’s essential to choose the right machine for your specific application, considering factors such as machine type, roller configuration, material type, roller diameter, and machine capacity. Understanding these factors will help you make an informed decision and optimize your bending processes. Profile bending machines have come a long way in providing versatile solutions for bending operations, including the ability to bend multiple radii efficiently and effectively.