Which press brake is best?

Question: We recently purchased a new press brake, and to tell you the truth, I&#;m not real happy with the results of my decision. My employees are not happy with the change. They seem to be struggling with learning the new technology and new ways of doing things on the press brake. They seem to spend more time setting up the new machine than they did using our old system.

We recently purchased a new press brake, and to tell you the truth, I&#;m not real happy with the results of my decision. My employees are not happy with the change. They seem to be struggling with learning the new technology and new ways of doing things on the press brake. They seem to spend more time setting up the new machine than they did using our old system.

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I&#;ve even spent a fortune on new tooling&#;tooling that doesn&#;t match our stock tooling. Just to keep production up, we will need to purchase additional adapters to accommodate all of our legacy tooling.

What should I have known before I spent all this money on a press brake and tooling? While you can&#;t help me with this purchase now, you can, I hope, prevent other shop owners in my position from making the same mistakes that I just made.

Answer: I am asked that question a lot, and even with plenty of experience answering it, I find the question by nature to be subjective. There is no &#;absolute best&#; press brake. There is, however, an absolute best press brake for you, and that really is the heart of your question.

Look at Your Operation, Not the Numbers

You&#;re pretty sure you need a new press brake. You&#;ve budgeted for the purchase, but what&#;s your return on the investment?

You have dozens of drive system types and styles to choose from. Which drive system is best? How much technology do you really need? To make a wise choice, you need a solid understanding of the different types of machines and their niche in the industry.

This is not an attempt to promote one type or style over another; it is meant to give you a basic description of the different styles of press brakes, tooling, and methods. This will allow you to make an unbiased comparison.

Mechanical

The mechanical press brake&#;s basic design comes from the early s. A flywheel provides the power&#;as much as 150 percent of the rated tonnage. Because of its design, a mechanical brake isn&#;t a realistic option for air bending in any production operation. Instead, these machines are mainly used for operations in which the inside radius is stamped at less than material thickness (coining) or at 20 percent above the material thickness (bottoming). For more details on the differences among air forming, bottom bending, and coining, see &#;Bending Basics: How the inside radius forms,&#; available at www.thefabricator.com.

This can be an adequate machine if you are making an occasional truck bumper or a hundred fence posts. However, precision work will take a craftsman, extra setup pieces, and a lot of production time. And because each bend angle requires a unique tool, you will need to handle the part multiple times as you work your way through the bends.

This machine is best suited for American planed tooling. It would be somewhat of a waste of effort to adapt precision-ground tooling as any precision gained from the tooling would be lost to the errors in the machine and drive systems.

Crude backgauging systems were and still are common, though computer numerical control (CNC) was not an option or truly available when most mechanical brakes were being manufactured. Many have tried retrofitting CNCs to mechanical brakes, but this has never seemed to work out well.

Not many mechanical press brakes are being made anymore, and for good reason: They are dangerous. While it is possible to install safety guarding, the guarding itself is functionally inadequate. Modern safety guarding retrofitted to one of these press brakes is somewhat akin to adding a state-of-the-art automatic, electric, antilock braking system to a Model T Ford.

For instance, in order for a light curtain to work, it would need to be placed approximately the same distance from the pinch point as where the operator needs to work. This means that the first time you&#;re not looking, the operator will disable the curtain.

Hydra- or Hydromechanical

This style was an early adaption of hydraulics to the press brake. In this design, motion from hydraulic oil pressure turns a hydraulic motor, which provides motion to the ram. This in turn provides full power at any point in the ram stroke.

Unlike the mechanicals, which provide full power only at bottom dead center of the stroke, the hydromechanical press brake is able to return to the open position from any point. Simple NCs control the backgauge, and some early versions had ram-axis control available.

These brakes are designed for American-style tooling. You can use adapters for European tooling, but you will lose a substantial amount of open height&#;that is, the working area between the ram and the bed.

Single-cylinder Hydraulic: The Bell Crank

The bell crank-style machine has a single hydraulic cylinder running parallel to the ram and bed. A change in angle of the linkage causes motion in the ram, a mechanism not unlike those used in older drum-style car brakes.

These machines aren&#;t very accurate when it comes to bend angles. However, because of the way the mechanism operates, the machine can produce high tonnage loads. You often find these brakes in heavy bending applications such as structural components for bridges and buildings. These brakes are designed for heavy-gauge applications and American-style planed tooling. They also generally have only the simplest numerical controls (NCs).

Internal-Stop (Stroke-Limited) Hydraulic

This press brake&#;s drive system, in simple terms, has &#;hard&#; stops&#;solid but adjustable limits within the hydraulic cylinder. While this improves repeatability over the mechanical press brake, the machine itself operates in a similar fashion.

When compared to the mechanical brake, this machine offers shorter setup times and requires less tryout material, but it&#;s still not very fast or efficient. Like the mechanical brake, the internal-stop hydraulic has no fixed reference point for ram axes control. You simply need to bend a test piece based on a best-guess depth of penetration into the die space, and then make adjustments to the penetration depth from there. Still, once the ram depth is tuned in, the control can be turned over to the NC, giving the operator control of both the ram and backgauge positioning.

These machines are designed for American-style tooling and, with adapters, can be used with European-style tooling, though again with a substantial loss in the open height.

CNC Hydraulic and Hybrid

These machines are driven by standard hydraulic systems, drawing from a shared oil reservoir or by closed individual systems working independently. The hydraulic pumps can be straightforward or &#;servo-over-hydraulic,&#; combining the accuracy of an electric press brake with the power of a hydraulic system.

Fixed reference points and high repeatability are the key phrases here. Of course, this comes at a price when compared to the previous two machine styles. Nonetheless, these machines offer quick setups and consistent bend angles, especially for air forming, the bending method preferred for these machines. While you can bottom-bend with them, you won&#;t be making the best use of the technology. You should also avoid coining, which can damage the press brake and tooling, not to mention the operator.

These systems have CNCs with multiple axes of control, each with high repeatability. The brakes can, depending on the manufacturer, be designed for use with all three tooling styles: American, European, and New Standard.

Electric

Fast and efficient, these press brakes have electric motors that drive the ram. To produce motion, motors can be attached directly to the drive screw or by way of a timing belt.

Electric motors will need to improve some before 300- to 500-ton machines make it to market. In the meantime, some press brake manufacturers have added a series of pulleys as a force multiplier. This mechanism also reduces the need for a crowning or antideflection device.

These machines are specifically designed for precision-ground tooling. Like using precision tooling in a mechanical press brake, using planed tooling will not give you the accuracy these press brakes are designed to achieve. These machines have CNCs that have precise control over multiple axes.

Controllers

Do you need CNCs with all the bells and whistles, or are you just aligning the punch to a scribe line? The choice really is yours. What are your production needs? If they include high-precision one-off parts or small-volume production runs, then a controller with a lot of options may be your best choice.

Before you purchase a machine with more than basic dual-axis control, consider your operators or, at the very least, your lead or setup people. Do they really understand what the functions are for? Consider the dwell function. Sure, it causes the ram to pause at the bottom of the stroke for a short period of time, but the question is: What, when, where, and how do I apply these functions? When picking a controller package, consider the cost of additional functions and how likely it is operators will use those functions.

Will you be purchasing new tooling? This may not be like the planed American tooling you already have, but rather precision-ground tooling, with which it&#;s implied that operators will be air forming.

Does this mean your staff will need to learn an entirely new way of doing things? Are they going to accept it willingly or will they pine for the old ways? I&#;m not trying to deter shop owners from making the leap; I&#;m just making an observation. It will be hard to justify the cost of the press brake if your operators opt for the old one they are familiar with.

What&#;s Next? Tooling

Before you can choose a new press brake, you need to understand the tooling. Picking the right press brake is as much about your tooling style and forming method choices as anything else. I would argue the type, style, and application of tooling is the most important part of your decision&#;but you&#;ll have to wait until next month for that part of the story.

When it comes to metal fabrication, the press brake is an essential piece of equipment for bending sheet and plate material, most commonly sheet metal. These machines range from small, manual devices to large, CNC-operated pieces of equipment designed for high precision work. Throughout the industry, several manufacturers have established themselves as leaders, providing a variety of press brakes that meet different technical requirements and cater to various sectors such as automotive, aerospace, and construction.

Established companies like Amada and Trumpf have a strong market presence due to their longevity and the innovation they bring to the table. Amada, a multinational entity since , has been among the top providers with a wide array of fabricating machinery. Trumpf, originating from Germany in , similarly boasts a history of technological advancements in machine tools, laser technology, and electronics. These manufacturers have built a reputation for reliability and excellence, standing out in a competitive market.

Alongside these industry giants, other manufacturers like Accurpress based in Canada have made significant contributions to the press brake industry with over 45 years of experience. They, along with companies from various regions, are shaping the way in which fabricators approach sheet metal bending, emphasizing improvements in precision, efficiency, and versatility. Each of these top manufacturers plays a pivotal role in supporting the metalworking industry with tailored solutions that keep up with evolving manufacturing demands.

Global Market Overview

The global press brake machine market is experiencing steady growth. By the end of , market size reached approximately $569.1 million. Projections suggest an upward trajectory, with an anticipated Compound Annual Growth Rate (CAGR) of about 6.1% from to . This growth could result in a market value crossing $1 billion by .

Manufacturers are driving innovation, embracing advanced technologies like hydraulics and pneumatics in press brake machines. The demand spans multiple industrial sectors, with applications ranging from automobiles to transport machinery and industrial equipment.

The market's competitive landscape features key players with a significant global presence. Amada, founded in , has gained recognition for specializing in sheet metal processing machinery. Another dominant force, Trumpf, established in in Germany, has shaped the market with its high-tech solutions comprising machine tools, laser technology, and electronics.

Region-wise, the market penetration is diverse, with Asia-Pacific, North America, and Europe serving as major contributors to industry growth. Innovations and technological advancements will likely continue to enrich the market dynamics, responding to the needs of the automotive, construction, and metallurgy industries.

Amidst these trends, sustainability and efficiency remain pivotal in influencing manufacturers' research and development efforts to meet market demand and regulatory standards.

Criteria for Evaluation

When assessing the top press brake manufacturers, one should consider a set of well-defined criteria to ensure an accurate and fair evaluation. These criteria typically focus on aspects that directly affect performance, reliability, and service quality.

Quality and Reliability: A manufacturer's reputation for building durable and high-performing press brakes is fundamental. Prospective buyers should examine the materials, technology, and engineering behind each product.

Innovation and Technology: Manufacturers that invest in research and development often lead the market in terms of innovation. Features like CNC systems and precision control should be weighed for their potential to increase productivity and accuracy.

Customer Service: After-sales support is critical, and manufacturers must offer comprehensive service, including maintenance and parts availability.

Product Range: The diversity of models available can cater to specific needs, from small businesses to large industrial operations.

Compliance with Standards: Compliance with international safety and quality standards ensures the press brake operates safely and meets performance expectations.

User Reviews and Feedback: Current user experiences can be indicative of long-term satisfaction and should not be overlooked.

Cost Efficiency: The initial investment and long-term operational costs need to balance with the expected performance outputs.

When evaluating the following top 10 press brake manufacturers, buyers should meticulously consider each of these factors to select the best machine for their particular needs.

Top Press Brake Manufacturers

The landscape of press brake manufacturers is dominated by companies renowned for innovation, precision, and quality in sheet metal fabrication. They invest in research and development to offer advanced features that cater to diverse industrial needs.

Amada Co., Ltd.

Amada, established in in Japan, is a prime manufacturer of metal processing equipment, providing highly efficient press brakes recognized for their precise bending capabilities and advanced features such as user-friendly control panels.

TRUMPF Group

Based in Germany, the TRUMPF Group offers a broad range of fabricating machinery. Its press brakes are known for their versatility and high-technology solutions aimed at optimizing production efficiency.

Accurpress America Inc.

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Accurpress America is a leading North American press brake manufacturer that offers customizable solutions, including their trademarked Accell Series, known for its durability and high-level bending precision.

Cincinnati Incorporated

Cincinnati Incorporated, headquartered in Ohio, USA, has a storied history of manufacturing. They produce robust and reliable press brakes that integrate advanced controls to simplify complex bending operations.

MC Machinery Systems, Inc.

MC Machinery Systems, a subsidiary of Mitsubishi Corporation, supplies metalworking industry with tooling systems including precise CNC press brakes geared towards space and time-saving in thick-gauge aluminum fabrication.

Durma

Based in Turkey, Durma offers a range of metal fabrication machinery. They are noted for their cost-effective yet powerful press brakes, providing a blend of performance and ease of use for operators.

LVD Company nv

LVD, a Belgium-based manufacturer, delivers innovative and high-performing press brakes. Precision and user-friendly interfaces are trademarks of their designs, catering to high-end metalworking demands.

Prima Power

Prima Power is an Italian multinational corporation known for its high-tech sheet metal working machinery. Their press brakes stand out for energy efficiency and integrated software solutions.

Salvagnini Group

Salvagnini, headquartered in Italy, automates the bending process with its press brakes that combine flexibility and speed, designed for lean production and adaptable to various industrial applications.

HACO Atlantic Inc.

Part of the global HACO Group and operating in North America, HACO Atlantic is respected for their reliable and serviceable press brakes, which are designed to enhance productivity and precision in metal fabrication.

Technological Advancements

The landscape of press brake manufacturing has been significantly shaped by recent technological innovations. Leading manufacturers are now incorporating dynamic crowning systems which substantially boost bend accuracy. These systems automatically adjust the press brake's ram in real-time, effectively compensating for any machine deflection that could affect the uniformity of the bend.

Moreover, the integration of high-speed hydraulics has led to increased efficiency in operations. These systems facilitate faster movement of the press brake components, thus reducing cycle times and enhancing productivity.

Here is a summarized list of key technological advancements:

• Dynamic Crowning: Ensures uniform bending by compensating for deflections.
• High-Speed Hydraulics: Increases machine speed and reduces cycle time.

Another significant stride in technology is the application of automation. Manufacturers are leveraging robotic systems, AI, and machine learning to enhance precision and safety while minimizing the requisite for manual intervention. The incorporation of these sophisticated technologies propels productivity forward and streamlines the manufacturing process.

With a continual emphasis on innovation, top press brake manufacturers are set to redefine the capabilities of metal forming equipment, establishing new standards for excellence in the field.

Industry Applications

Press brakes play a crucial role in various industries due to their capacity for precision bending and shaping of materials. These machines are essential in sectors including:

• Aerospace: Fabrication of aircraft parts where precision is paramount.
• Automotive: Shaping components like car frames and chassis.
• Construction: Creating structural elements such as beams and frames.

Materials handled by press brakes:

• Metals (e.g., steel, aluminum)
• Plastics
• Composites

With advancements in technology, manufacturers have introduced models capable of working with a diverse range of materials, catering to industry-specific needs. They provide solutions that range from small, intricate components to large-scale industrial parts, making them versatile tools for production lines.

Application in Detail:

• Metal Fabrication: A primary application, it involves bending sheet metal for products like enclosures, panels, and brackets.
• Custom Production: Small batches of custom parts are produced for specialized machinery or unique projects.
• High Volume Manufacturing: Efficient production of repetitive, standardized parts for consumer goods.

The technology has evolved to meet safety standards and efficiency demands, integrating features such as CNC controls and safety light screens, as seen in the SafanDarley E-Brake, ensuring operators' safety and enhancing productivity. This adaptability cements press brakes' importance across different manufacturing domains.

Customization Capabilities

In the realm of press brake manufacturing, customization is key for clients with specific, often complex requirements. Top-tier manufacturers offer tailored solutions, ensuring that every press brake not only fits within a user's workflow but also enhances their operational efficiency.

LVD and PrimaPower are notable for their adaptability in producing customized press brakes. They provide extensive options ranging from manual setups to advanced multi-axis CNC systems. LVD places a strong emphasis on their proprietary adaptive forming systems and touchscreen control interfaces, offering an intuitive user experience.

PrimaPower shines with its comprehensive coverage in sheet metal processing technology. Their customization extends to integrated systems accommodating varied processes like laser processing, stamping, shearing, and bending, as well as automation capabilities.

Manufacturers often divide their customization capabilities into:

• Control Customization: Touchscreen interfaces, software integration, and user-specific controls.
• Mechanical Customization: Variable tonnage, size dimensions, and multi-axis backgauges for precision bending.
• Accessory Options: The addition of safety systems, tooling variations, and material handling systems to enhance productivity.

Clients should inquire about the manufacturer's ability to meet specific standards and the extent of customization offered to ensure they receive a press brake that aligns perfectly with their operational requirements. The manufacturer's expertise in adapting to client needs is a crucial aspect of the selection process.

After-Sales Services

When selecting a press brake manufacturer, after-sales services are an integral factor to consider. Manufacturers with a strong support network often provide various services to ensure optimal operation and longevity of the equipment.

• Technical Support: Manufacturers typically offer a hotline for immediate assistance, guiding clients through troubleshooting procedures.
• Spare Parts: A reliable supply of original spare parts is vital for maintenance and repairs. Established manufacturers usually have a systematic parts inventory to minimize downtime caused by part shortages.
• Training Services: To guarantee proficient use of press brakes, some manufacturers conduct training sessions for machine operators, ensuring they are well-acquainted with the equipment.
• Maintenance Agreements: Regular maintenance is critical for performance and safety. Manufacturers may offer maintenance agreements to help prevent potential issues before they escalate into costly repairs.
• Warranty Services: A comprehensive warranty policy is a mark of confidence in the product's quality. This often includes coverage for certain parts and labor for a defined period.

The following table summarizes the after-sales service components provided by top manufacturers:

Service Type Description Technical Support Hotline for immediate troubleshooting assistance. Spare Parts Organized inventory of original parts for the machine. Training Services Operator training for efficient and safe machine use. Maintenance Agreements for scheduled upkeep to prevent malfunctions. Warranty Coverage for parts and labor for a specified term.

These services collectively ensure that the operational lifespan of press brakes is maximized, while also providing peace of mind to the customer that support is readily available when needed.

Future Trends in Press Brake Manufacturing

Automation: The integration of robotics and automation systems is becoming increasingly prevalent. Manufacturers are incorporating these technologies to enhance precision, speed, and safety while minimizing labor costs.

Energy Efficiency: Press brake manufacturers are focusing on building machines that consume less energy. Advanced hydraulic systems and electric press brakes are being designed to optimize power usage.

Smart Controls: Enhanced control systems using IoT (Internet of Things) and advanced software enable better monitoring and control of press brake operations, ensuring higher accuracy and connectivity for predictive maintenance.

• Customization: Manufacturers are offering more tailored options to meet diverse customer needs, with a shift towards modular designs that allow for easy upgrades and customizations.
• Material Advancements: Usage of high-strength materials is increasing, requiring press brakes to handle tougher metals with precision.

Operator Training and Safety: Industry leaders are investing in creating safer work environments with features like light curtains and laser-based monitoring systems and focusing on ergonomic designs to reduce operator fatigue.

• Hybrid Models: Combining hydraulic force with electric servo motors provides a balance between force and energy efficiency.

3D Printing and CAD Integration: There's a growing trend toward integrating press brakes with 3D printing technology and CAD software, facilitating rapid prototyping and streamlined production processes.

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