Aluminum Sheet Metal Bend Radius Chart

The minimum bend radius data shown in these charts is measured to the inside of the bend. Radii for various thicknesses expressed in terms of thickness t. Aluminum minimum bend radii for 90 degree cold forming of sheet and plate.

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Material bend radii and minimum bend size charts please note.

Aluminum sheet metal bend radius chart.

Use the minimum bend dimension values in the charts below for your minimum closeness of cutout to a bend. The material thickness will be measured in decimal form not by the gauge number. Per the aluminum association inc. You will need to know your material thickness mt the bend angle b the inside radius ir and the k factor k.

The tables below show bend radii and minimum bend sizes for materials and tooling combinations stocked by protocase. We go beyond the general rules of sheet metal bending as our customers want tight bend radii for sheet metal parts. The bend radius you select may not be available if the geometry of the part will not allow us to bend with the specific tooling required to achieve that radius. The bend allowance formula takes into account the geometries of bending and the properties of your metal to determine the bend allowance.

The bend radii listed are standard minimum if manufacturing for aircraft and aerospace applications. It is possible to choose other bends if you require but additional lead time and tooling charges may apply. Sheet metal bend radii if these guidelines are not followed more research and or some form of analysis may be requried. Since commercial sheet metal bending can be done with less concern for stresses caused during forming operation the radius can be near zero for thin sheet metal.

Table 1 preferred recommended 90 degree bend radii for various sheet metals.