World-Class Metal Tube Fabrication
BTD's Tubing Department creates industry-leading engineered tube products through precision Tube Cutting and Tube Bending, producing components for Tubular Weldments and Assemblies that deliver real value.
BTD pairs precise Laser and Saw cutting with CNC bending operations across Steel, Alloy Steels, Aluminum, and Stainless Steel. Round, Square, Rectangle Tubing, solid rounds, bars, and special shapes. Our specialized bending equipment handles pieces up to 14 feet long, ranging 0.500" through 6.0" diameter.
Precision Tube Cutting: Laser & Saw Processing
BTD utilizes state-of-the-art 3D Tube Lasers and Vertical and Horizontal Band Saws for precision processing across a wide range of tube materials.
Tube Laser Processing
BTD tube lasers maximize material use and precision through:
- Active Scan — Scans every tube and auto-corrects part programs to ensure accuracy despite common deformations like twisting and bowing
- Active Tilt — Processes bevel and chamfer features up to 45 degrees
- Active Shape — Cuts non-traditional shapes such as roll forms
Materials We Specialize In
| Material | Min OD | Max OD | Max Wall |
|---|---|---|---|
| Steel (A513, A500 series) | 0.500" | 6.0" | .375" |
| Alloy Steel (4130/4130N Seamless) | 0.500" | 6.0" | .375" |
| Aluminum 6061 Extrusions/Draws | 0.500" | 6.0" | .250" |
| Stainless Steel 304 & 316 | 0.500" | 6.0" | .250" |
Band Saw Processing
BTD's saws process Steel, Tool Steel, Channels, Angles, Beams, Aluminum, Stainless Steel, Alloys, Non-Alloys and more in all shapes and sizes.
- Bundle or material sizes up to 18.75" x 29.5"
- Horizontal and Vertical Tilting up to 60 degrees
- Cut tolerance +/-.015 to +/-.030" depending on material
- Lengths from less than 1 inch up to 30 feet
- Bundle cutting available to maximize efficiency
Metal Tube Bending Services
Our tube bending capabilities draw from an expansive library of 180+ tool sets and growing. We handle tubing diameters from 0.500" up to 6.0" with centerline radius up to 450mm (17.71"). Multi-Tool Stack bending accommodates different bend radii on the same part.
Tube Bending Manufacturing Methods
Mandrel Tube Bending
Fully retains the internal tube profile throughout the bend using internal mandrel support. Ideal for thin wall thickness, large diameters, and tight radii where collapsing is common. Can be paired with a Wiper Die to prevent wrinkles on the inside bend radius.
Rotary Draw Tube Bending
The most popular method. Uses a clamping die, radius die, and pressure die to draw the tube around the bend die via hydraulic or electrical power — producing highly accurate, repeatable bends. Supports mandrel and wiper tooling for superior material flow control.
Roll Tube Bending
Three rollers lock the tube while a piston applies gradual force, "rolling" the tube through to create an arc. The process repeats until the desired profile is achieved.
Variable Radius Bending
Similar to roll bending but executed in electric CNC tube benders for more precise, repeatable results. Minimum radius: 10x tube diameter for round tubing.
Compression Bending
Tube is clamped in place and force is applied directly. Best for single-bend applications. No internal support — typically produces an oval cross-section.
RAM Tube Bending
A hydraulic ram pushes the radius die into the tube. Cost-effective with lower tooling costs and faster cycle times. Best suited for single-bend, less complex parts.
Split Die Tube Bending
Designed for square and rectangular tube bending. Split Die actuators compress tooling onto the tube through the bend to hold its shape, resulting in reduced deformation.
Modular Drilling
Used for adding holes that are in or near bends where laser processing will not work. Laser processing in these zones would cause the tubing to tear or for the hole feature to be severely deformed during the bending operation.
Design Considerations for Tube Bending Manufacturing
Round Tube:
- Typical CLR = 2x tube diameter (can be reduced with softer material or mandrels)
- Distance between bends = 2x OD for tubes ≤1.0" / 3x OD for tubes >1.0"
- Special tooling can reduce or eliminate the distance between bends (reviewed part by part)
Square Tube:
- Typical CLR = 3x tube size
- Distance between bends = 3x tube diameter
- Can be reduced with special tooling (reviewed part by part)
For multi-bend parts, maintain a consistent bend radius across all bends.
