About the sheet metal folding process

The metal folding process at KMF usually starts with the programming and design teams who help determine the most efficient machines, materials and methods to use to manufacture the finished metal component.

A range of press brake tools are available at KMF and the choice of machine depends on the requirements of the sheet metal component.

Design engineers consider such things as material thickness, bend radius and batch size to select the most appropriate machines and tooling.

The majority of the metal components manufactured at KMF have undergone punching or laser cutting before metal forming and engineers will use a product route card to track progress through the metal folding areas.

Metal components can be folded manually on a press brake machine or programmed on automated folding cells.

Automated CNC metal folding programmes determine the angle and movement of the press brake tools and hydraulic rams as electrical servo motors provide the force to form a shape in the sheet metal.

KMF’s modern metal fabrication facilities currently operate 21 press brakes, two automated panel bending machines and two robotic metal folding machines. Our CNC folding machines have varying capabilities and a maximum bend length of just under four metres.

Robotic bending

KMF’s robotic folding technology includes two Trumpf bending cells – a Trubend Cell 7036 and Trubend Cell 5170 – which offer automated tool selection, material loading and a conveyor system for flexible storage.

These metal folding machines are the ideal solution for high-volume part production. The ability to operate ‘lights out’ allows for a fast, precise and cost-effective metal bending solution.

Our quality teams carry out in-process quality checks throughout the fabrication process to ensure high repeatable accuracy while advanced 3D measurement technology guarantees all components meet the very tight tolerances required by many KMF metal forming customers.

Automated panel bending

Automated panel bending machinery at KMF includes a Salvagnini P4L-2516 and a Salvagnini P4-1916.

This advanced metal fabrication equipment can achieve unique geometries far greater than press brake forming and, as a result, can provide customers with opportunities to improve on product design.

Equipped with universal bending tools, KMF can guarantee productivity and deliver expanded forming capabilities such as large radius CNC bump forming, down bend negative forming and reverse flanges.

Press brake forming

Extensive press brake forming capacity at KMF includes Trumpf Trubend, Amada and Bystronic Edwards Pearson machines.

Press brakes can often handle a broader range of material thicknesses than panel benders which favour light gauge sheets and therefore are often more versatile.

The combination of universal bending tools and world-class metal folding technology with varying capabilities means KMF can guarantee high productivity in the manufacture of almost any metal enclosure, panel, bracket or component.

Components vary in complexity, from small parts with a single bend through to large segments with many bends and multiple flange lengths.KMF has the capacity and equipment to provide a vast range of metal fabrications for many industries, including kiosk, vending, aerospace, food and packaging and scientific equipment.

Find out more about KMF’s extensive customer base and product experience.

KMF can fold, bend and form an extensive range of sheet metal materials of varying size and thickness depending on the metal folding technology.

The range of materials formed at KMF includes mild steel, galvanised steel, stainless steel, zintec and aluminium.