Do I need a press brake or a metal folding machine for my plant?

We have always stressed the importance of press brakes and metal folding machines. We have also mentioned the correlation between them and how crucial it is to have both machines cooperating on your shop floor.

Each of these machine systems has its advantages and disadvantages. By understanding them, we can achieve greater results, avoid common mistakes, and be more efficient.

After all, the goal is to choose a machine with a great return on investment, guaranteeing high-quality products and the highest productivity levels. But if you’re planning to invest in just one new machine for your plant, which one would you choose? That depends entirely on your plant’s needs.

Before starting your journey, identify what you are lacking and how will the new machine fulfil your requirements. After that, make sure to estimate a budget that you can afford and that you think is reasonable. Then, start your research about both types of folding machines.

In this article, we are going to compare a press brake with a metal folding machine.

This comparison aims to show you how they perform in similar situations with similar workpieces, filtering your options until reaching the final decision. For further information on folding automation machine systems, feel free to reach our technical sales team.

Bending Sequence

The bending process is made of several steps that need to be followed by operators to achieve the desired result. When planning bending sequences, operators should pay attention to the bending tools they will choose, the sheet metal, and the production methodology. But programming bending sequences are different for press brakes and sheet metal folders.

For press brakes, the blank is positioned outside the machine. The operator has to hold and support the blank’s weight. Furthermore, during bending, the upper ram moves down towards the lower die. Then both sides of the part move up and leave the plane.

For sheet metal folders, the blank rests on the support table during the folding process, where a gauging system positions the part to the bend line. The upper and lower beam clamp the blank. In contrast to the press brake, the folding beam goes up and gets positioned in a pivot point during bending. In a metal folding machine, the direction of the folding beam depends on the bending direction.

The differences are that when you work with a press brake, you will definitely need skilled operators because they cannot perform the task alone. On the other hand, in sheet metal folders, you need just one operator, and the process is way less backbreaking and easier.

This brings us to another advantage of sheet metal folders. When you work with a folder, the sheet metal rests on the table. In press brake folding, operators need to lift and hold the sheet metal during the whole forming process. This raises other health and safety issues. After some time, a lot of operators suffer from shoulder problems. Also, when this task is done continuously, operators get very fatigued holding and positioning the sheet, affecting the quality of work significantly.

When working with folding machines, there’ no fatigue; the gauge helps to position the sheet accurately every time, and the whole task is faster to complete, reducing bending cycles and saving time.

Material specifics

The main difference between press brakes and metal folding machines is how they handle the material. A press brake puts the material in between the punch and the die. The punch contacts the material from above, while the die goes below. In metal folding machines, the material is sandwiched between the two parts, and the machine performs the bending moving only the desired angle.

This makes the metal folder’s bending have a higher angle accuracy, with fewer contact points with the material. Also, because metal folders have only one contact point when forming and the material is well-supported between the machine, the level of accuracy does not get affected when we are working with a high thickness sheet metal.

Because of its bending methodology, metal folding machines are a good choice for fragile materials. The sliding area of the tools on the material’s surface is less than in a press brake forming, as metal folders do not operate with a punch and die. This eliminates scratches and other visual imperfections on sensitive materials.

Setup and Tooling

Our previous articles have tackled the importance of the setup process and configuration for press brakes and metal folding machines. When put to the test, both machines can deliver high-quality results, but setting up a press brake is more complex because you need to change the tools to continue to perform different applications. The big benefit of metal folders is their efficiency when it comes to tooling.

As we said earlier, metal folders can handle different material and thicknesses without changing tooling and accessories. So, we have minimal setup times and costs compared to a press brake, which needs several tooling and bigger investment sets.

What makes metal folders even more efficient is that tooling does not wear easily because the movements and contact points are fewer than a press brake. This guarantees the longevity of parts and eliminates the need to replace them from time to time.

When it comes to different applications, press brakes require special tooling for open, closed, or teardrop hems. A bending radius is also very difficult and time-consuming to perform in a press brake. As gauging is partial, the operators need to hold the material the entire time, and each step takes longer than a folder’s radii.

Conclusion

Press brakes and metal folders; What to use when?

The most important message you can take out of comparing press brakes and metal folding machines is that they are definitely not the same, and they definitely should not be used as a replacement to one another.

For big volume production, opt for a press brake, as they are relatively faster.
For medium or small batch production, a folding machine can very well get the job done.
If you work with big workpieces, a folding machine is better, less labour-intensive and more efficient.
If you work with small workpieces, a press brake delivers fast and better.
For sensitive materials, pre-painted workpieces or complicated applications with lots of tooling setups, head for a folding machine.

There is no one-size-fits-all formula. Think about your plant’s capacity and line of work, and seek guidance from professionals. Our team can help you find a personalised solution for your situation.

Feel free to contact us anytime, and we will get back to you at once.