Achieving bending efficiencies with panel benders

Jun. 24, 2024

Achieving bending efficiencies with panel benders

The ubiquitous press brake is hard to miss in the world of metal fabricating. The panel bender, meanwhile, is not so prevalent. But maybe that is changing.

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Metal fabricators are constantly looking for shop floor efficiencies, and as a result, they need to be open to technologies and processes that they may not have considered before. That&#;s where panel benders come in. They can produce bends, like a press brake, but they often can do it more efficiently and without the requirement of having a skilled machine operator at the helm.

From a technology standpoint, the panel bender relies on bending blades to make the programmed bends, instead of a ram that forces the sheet metal blank into a die opening. A machine operator inserts the blanks into the machine where hold-down clamps keep the blank from moving while a pair of bending blades contact the material to make upward or downward bends. The blades do not move in a straight up-and-down line, but rather oscillate around a single bend point until the desired angle of the bend is achieved.

Older panel benders require operators to switch out tooling manually. But like more modern press brake setups, panel benders have evolved to incorporate automated tooling changeovers as well, minimizing the machine operator&#;s interaction.

To further understand how panel bending fits into a modern metal fabricating operation, let&#;s look at how two companies are using the technology to stay on top of increased production demands. Datum Storage Solutions Inc., Emigsville, Pa., and NSA Industries LLC, St. Johnsbury, Vt., adopted panel bending for different reasons, but they are finding that it&#;s delivered a similar result&#;additional bending capacity when they needed it most.

The Panel Bending Veteran

Almost 20 years ago, the owner of Datum Storage Solutions asked Brett Eaton and his co-workers to check out a video he had seen about a bending machine that he thought could help them. Eaton, then a press brake operator, saw the same potential in the panel bender that the owner saw.

&#;We were like, wow, this could be a big help to us,&#; he said.

In Datum purchased a

In Datum purchased a Salvagnini P2 panel bender and put it to use bending low-volume jobs, typically 20- to 16-gauge in thickness. Impressed with the panel bender&#;s performance, the manufacturer of shelving and storage products purchased another P2 two years later. The company pretty much has been running those two machines nonstop over two shifts since then.

&#;We used to bend everything on a press brake. We would have an operator set them up, bend a couple of pieces, and then change over the tooling for another job,&#; Eaton said. &#;What really drew us to the panel bender was the setup time and the bending speed. It was completing bends in 40 to 45 seconds, whereas it was taking the press brake operator a minute to a minute and a half.&#;

To illustrate the more efficient setups, Eaton pointed to Datum&#;s four-post shelving products as an example. When it was bent on a press brake, operators had to set up two different stations on the brake, placing both the forming tools and dies in the right place, to complete the 135-degree bends necessary for the posts. To change the tooling on a semiautomatic panel bender, the operator unlocks a lever on one of the machine&#;s sides, slides the tooling in, and locks it back up; the same steps are repeated on the other side of the machine.

&#;So you&#;re looking at a three- to five-minute setup on the panel bender compared to 10 to 15 minutes on the press brake,&#; Eaton said.

The quick tooling changeover is pretty important because Datum does quite a few of them over a shift. Eaton said the company averages 10 to 15 setups per shift between the two P2 panel benders and two punching machines that make up a cell. The jobs are run according to length. For instance, the operator that runs all four machines in the cell will set up 36-inch parts and run all that size. Then a tool changeover will occur to run 42-in. parts.

In all, Datum has five common lengths: 24, 30, 36, 42, and 48 in. It also offers a range of widths, starting at 9 in. and going to 48 in., increasing in 1-in. increments. Additionally, all of these offerings might require some combination of knockouts, perforations, punches, and slots. These and other options also are available in shelving in the four-post line.

&#;There are days when the operator will do upwards of 30 to 40 setups when they are running oddball jobs,&#; Eaton said. &#;We generally run the oddball parts once a week.&#;

Even with the changeovers, Datum has one operator tending this workcell. How is that done? The operator places a blank in the punching machine, while taking the already punched part off, and then initiates the punching cycle. The operator then walks to the panel bender and loads the punched part while pulling the bent part from one panel bender. At this time the bending cycle is initiated. The bent part is stacked on a skid, and the operator walks to the other punching machine, where the previous actions are repeated. When the bending cycle is initiated on the other panel bender, the operator then repeats this process, depending on quantities, of course. The operator does a figure eight through the area all day, maintaining all four machines.

&#;We get about two complete parts out of the cell every minute,&#; Eaton said.

The parts coming off the panel bender also are more accurate, according to Eaton. That&#;s a benefit for the welders downstream as tighter fit-ups mean welding can be completed more quickly.

&#;It&#;s more reliable because you don&#;t have the human error,&#; Eaton said. &#;You don&#;t have anyone pull off the backstops, for example. You don&#;t have to worry about that type of thing.&#;

The Panel Bending Convert

From its humble origins as a contract manufacturer in , NSA Industries LLC has grown into one of the largest metal fabricators on the East Coast. This is the result of a very aggressive acquisition campaign, growing with existing customers, and even launching its own product lines.

The owners of the company are committed to adopting new technology as one way to keep ahead of competitors. It&#;s one of the reasons NSA Industries has invested more than $19 million in capital equipment since the Great Recession. It&#;s also one of the reasons that the company is now involved in panel bending.

A private-label manufacturing job required plenty of new fabricating capacity in . The customer was looking for more manufacturing help, and NSA Industries was willing to oblige. To take on this new cabinet work, the fabricator wanted to invest in the latest automated equipment, such as a new solid-state laser cutting machine and a robotic welding cell. It looked at a Salvagnini P2 panel bender to handle a majority of the bending work.

&#;We were looking at the need for press brake operators, and finding experienced press brake operators is difficult,&#; said Matt Smith, vice president of sales, NSA Industries. &#;That&#;s when we started investigating the panel benders. When our guys went out and saw them run, it quickly made sense this was right for us.&#;

After the investment was made in the first P2, NSA Industries realized that it was the right equipment for the work, which was mostly in the 20- to 16-gauge range.

&#;As far as training, it was only a couple of hours, not months, that were needed to get an operator in the position to run the machine once it was programmed,&#; Smith said.

NSA Industries purchased another P2 panel bender shortly after installing the first one. About a year after that, the fabricator added a P1 panel bender, which fits in an 86-square-foot space.

Not only have the panel benders taken on more work because of the automated nature of the bending, but the units also have helped out with more complicated work, such as hems. Smith said it was once common to see a press brake operator using two press brakes to complete a hem, beginning on one setup to make the first bend and then completing the flattening of the material on another setup in the second brake. Now the panel benders can do the job on one machine and using the same tooling.

And the automated tooling setup on these new units was a big attraction as well for NSA Industries.

&#;For example, when you want to change your radius on a part, you don&#;t have to do a completely different tooling setup. The machine will hold the metal and then move the tooling into position to deliver the radius you want,&#; Smith added.

The Plans for More Panel Bending

One company has been panel bending for almost two decades, and one is really just getting started. Both plan to invest in more panel bending capacity in the future.

By the end of the year, Datum will add a large P4 panel bending machine and attach it to its 7-year-old Salvagnini S4 punching and shearing machine to create an automated workcell where a blank will be turned into a punched and bent part without any human intervention. Eaton said that the company is even thinking about adding a welding cell right beside this punch/panel bending cell to further reduce material handling.

The new equipment will play an important role in being able to produce much larger parts for new jobs, such as weapons storage cabinets. Datum&#;s P2s can handle a blank up to 74 in. diagonally; the P4 will be able to accommodate blanks up to 108 in. Eaton said those much larger blanks currently are being bent on a press brake and require two people to handle them during the bending process.

&#;I&#;m predicting that I can reduce my manpower on my press brakes by four people once we get this one machine,&#; Eaton said.

NSA Industries remains in active acquisition mode. It acquired a Massachusetts machining company in , a New Hampshire metal fabricating company in , and another fabrication company in Massachusetts in .

&#;Some of the acquisitions that we have made certainly have work that would be a better fit on a panel bender. Eventually we might bring some of that work to our main plant, and then I suspect that we may buy another panel bender for another facility,&#; Smith said.

Panel Bender Market Size, Projections: Share, Trends, and ...

New Jersey, United States,- Panel benders are advanced machines utilized in the manufacturing industry for bending various types of panels, including sheet metal, aluminum, and other materials. These machines offer precise control over the bending process, ensuring accurate angles and dimensions according to the specifications provided. Panel benders are equipped with sophisticated automation features such as CNC (Computer Numerical Control) systems, allowing for efficient production with minimal human intervention. These machines are integral in industries like automotive, aerospace, construction, and electronics, where precise panel bending is crucial for producing high-quality components and products. Opportunities in the panel bender market stem from the growing demand for automation in manufacturing processes, driven by the need for increased productivity, accuracy, and cost-efficiency. As industries strive for leaner production methods and higher output rates, panel benders offer a solution by streamlining the bending process and reducing cycle times.

Segmentation of the panel bender market can be based on various factors, including type, application, end-user industry, and geography. Types of panel benders may include hydraulic, pneumatic, and servo-electric models, each offering unique advantages in terms of speed, precision, and energy efficiency. Applications of panel benders span across a wide range of industries, from automotive body panel manufacturing to HVAC ductwork fabrication. End-user industries for panel benders encompass automotive, aerospace, electronics, construction, and others requiring precise metal bending capabilities. Geographically, the market for panel benders is distributed across regions with significant manufacturing activities, including North America, Europe, Asia Pacific, and Latin America. Each region may exhibit varying demand patterns influenced by factors such as industrial growth, technological advancements, and market maturity.

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Panel Bender Market Size And Scope:

The Panel Bender Market is poised for substantial growth in the coming years, driven by several key strategies and factors. Market players are increasingly focusing on product innovation and development to meet evolving consumer demands and preferences. Expansion into emerging markets and strategic partnerships or collaborations are also pivotal strategies for market growth. Additionally, investments in research and development to enhance technological advancements and improve product quality play a vital role. Moreover, the market's future scope looks promising due to the rising adoption of digitalization and the integration of advanced technologies, which are anticipated to open new avenues for growth and innovation.

Top Panel Bender Market Companies:

Salvagnini
Danobat Group
Prima Power
Smart CNC
AMADA GmbH
Komachine Co
Jinan Senfeng Laser Technology Co.
Ltd
Mitra Sejati Mesindo
Multifold Machinery Mfg. Co.
KR Machinery
Leabourn & Rose Ltd
Boiler Machines
Wuxi Shenchong Forging Machine Co. Ltd.
Kaifeng CNC

Panel Bender Market: Segmentation

To offer a holistic view of the Panel Bender Market, we employ a segmentation approach. We categorize the market into segments based on criteria such as product types, geographic regions, and consumer demographics.

Each segment is scrutinized to reveal specific trends, growth potential, and challenges. This segmented analysis empowers businesses to tailor their strategies to distinct market needs, enhancing their competitive edge. Our segmentation analysis is a strategic tool that guides market participants in navigating the complexities of the Panel Bender Market effectively.

Global Panel Bender Market by Type

Fully Automatic Panel Bender
Semi-automatic Panel Bender
Other

Global Panel Bender Market by Application

Household Appliances
Industrial
Aeronautics and Astronautics
Automobile
Other

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Reasons to Procure this Report:

(A) The research would help top administration/policymakers/professionals/product advancements/sales managers and stakeholders in this market in the following ways.

(B) The report provides Panel Bender market revenues at the worldwide, regional, and country levels with a complete analysis to permitting companies to analyze their market share and analyze projections, and find new markets to aim for.

(C) The research includes the Panel Bender market split by different types, applications, technologies, and end-uses. This segmentation helps leaders plan their products and finances based on the upcoming development rates of each segment.

(D) Panel Bender market analysis benefits investors by knowing the scope and position of the market giving them information on key drivers, challenges, restraints, and expansion chances of the market and moderate threats.

(E) This report would help to understand competition better with a detailed analysis and key strategies of their competitors and plan their position in the business.

(F) The study helps evaluate Panel Bender business predictions by region, key countries, and top companies' information to channel their investments.

Frequently Asked Questions

1. What is the current size and growth potential of the Panel Bender Market?

Answer: Panel Bender Market is expected to growing at a CAGR of XX% from to , from a valuation of USD XX Billion in to USD XX billion by .

2. What are the major challenges faced by the Panel Bender Market?

Answer: Panel Bender Market face challenges such as intense competition, rapidly evolving technology, and the need to adapt to changing market demands.

3. Which Top companies are the leading Key players in the Industry?

Answer: template_keyplayers are the Major players in the Panel Bender Market.

4. Which market segments are included in the report on Panel Bender Market?

Answer: The Panel Bender Market is Segmented based on Type, Application, And Geography.

5. What factors are influencing the future trajectory of the Panel Bender Market?

Answer: Industries are predominantly shaped by technological advancements, consumer preferences, and regulatory changes.

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Achieving bending efficiencies with panel benders