How to Complete 180° Bending Aluminum Extrusion?

I once cracked an aluminum profile trying a 180° bend without support. I learned the hard way—tight curves need planning, tools, and technique.

To complete a 180° bend in aluminum extrusions, use rotary-draw bending with mandrels, apply moderate heat, and maintain the correct bend radius.

Let’s go deeper into each question to help you get consistent, crack-free results.

What’s the best method for 180° bends in aluminum profiles?

Different tools suit different needs. Here’s how I pick the right bending method:

Rotary-draw is best for sharp 180° bends. It supports the profile with a mandrel inside the curve, keeping the walls from collapsing or cracking.

Can extrusion be pre-bent or require secondary operation?

I’ve been asked if we can extrude the 180° shape directly. The answer is always no.

Aluminum extrusion must be straight. Bending always happens in a secondary operation.

Extruding a curve would create uneven wall thickness, weak spots, and tooling issues. Instead, we extrude the profile straight, then bend it using a machine.

That gives clean shape, precise dimensions, and control over wall integrity.

How to avoid cracking during tight bends?

Tight bends stress the outer radius of the aluminum. Cracks appear if:

• The bend radius is too small
• The alloy is too brittle
• There’s no internal support

To avoid cracking, use the correct radius, add mandrels, heat the profile gently, and bend slowly.

My Checklist to Prevent Cracks:

1. Minimum Radius: Follow alloy-specific rules. For 6061-T6, don’t go below 2.5x wall thickness.
2. Support with Mandrel: Especially for hollow or thin-wall extrusions.
3. Pre-Heat Zone: Raise temp to ~200–300?°C to improve ductility.
4. Slow Bending Speed: Let the aluminum deform gradually.
5. Overbend to Compensate Springback: CNC machines can help with this.

What tools are needed for precise 180° bends?

To bend aluminum cleanly and precisely, you’ll need a mix of machines and tools:

For low-volume or manual needs, some operators use handheld benders with mandrel inserts—but this is only safe for soft alloys and thin-walled profiles.

Conclusion

180° bends in aluminum extrusions require planning. Use rotary-draw bending for tight curves, support the profile inside, apply heat, and bend slowly. Avoid direct bending during extrusion—always use a secondary operation.