A growing movement to increase domestic production has manufacturers taking a closer look at a key process in fabrication: bending. Press brake technology can have a significant impact on a company’s production success, so it makes sense that companies are investigating how better bending technology could make their overall production process more competitive.
Reshoring allows for better oversight of manufacturing processes, and advances in modern bending and automation technology make it possible to achieve the quality, flexibility and efficiency that are essential in the current market. Here, we take a look at some press brake and automation technologies that can help meet the requirements for successful local manufacturing.
1. Quality
To justify reshoring, manufacturers must ensure high-quality part production. Accurate bending is essential to achieving this goal. Fortunately, advanced press brake technologies enable any press brake operator – even a new or inexperienced one – to produce quality parts from the outset.
One advanced technology facilitating higher quality bends is TRUMPF’s Automatically Controlled Bending (ACB) technology. ACB systems continuously monitor the bending angle in real time, which allows machines to make immediate adjustments to accommodate for variations in the material grain and thickness. This not only enhances bending precision but also reduces the likelihood of defects. By optimizing bending parameters for specific jobs, ACB minimizes the need for secondary operations like rework.
Another technology assisting operators in positioning and bending parts correctly is TRUMPF’s Part Indicator. Part Indicator shows operators an augmented reality view representing how the flat part should be placed against the backstop. If the part is misaligned or incorrectly oriented, the machine control highlights the issue with a red indicator, prompting corrective action. When placed properly, the part shows up on the machine control as a green image and the operator can bend it confidently and correctly.
Handling large or cumbersome parts can lead to inconsistent results. TRUMPF addresses this issue at the press brake with bending aids that support material handling and enhance ergonomics. These aids ensure precise part positioning and minimize inaccuracies and defects. Bending aids are particularly useful for processing large heavy parts or thin sheets prone to back bending. By maintaining consistent bending angles, bending aids can significantly contribute to the high-quality output requirements of reshored work.
2. Flexibility
Flexibility is another essential element manufacturers need to adapt to changing market demands and consumer preferences resulting in greater customization. Being able to quickly pivot to accommodate new orders or adjust for new product variations can create a competitive advantage. Modern press brakes offer the flexibility that allows manufacturers to better meet customer needs, ultimately fostering sustainable growth.
One tool for greater flexibility in bending is TRUMPF’s 6-axis backgauge, an advanced press brake feature that significantly enhances flexibility in the bending process. Six-axis capability means the backgauge can move in multiple directions, allowing for vertical, horizontal and lateral adjustments. This versatility means the press brake can accommodate a wide range of part shapes and sizes, including complex designs, without extensive machine reconfiguration. The ability to handle intricate designs in a single setup reduces downtime and enhances productivity.
In addition, TRUMPF’s I-axis press brake feature improves flexibility by enabling CNC-controlled, real-time adjustment of the lower die bed position. I-axis allows operators to perform multiple forming operations such as air bending, hemming and Z-bends using a single tool setup. This flexibility enables operators to efficiently manage various bending features without having to change tools or reconfigure the entire setup for each job.
Operators can tailor the bending process to accommodate complex geometries, varying material thicknesses and different material types. This adaptability is crucial for manufacturers that produce a diverse range of parts, products or custom orders. Lower tool displacement also speeds up the bending process by reducing secondary operations, ultimately enhancing efficiency and turnaround times.
Software solutions like TRUMPF’s TecZone Bend further enhance flexibility in the bending process. This user-friendly software tool offers simulation capabilities, automatic parameter calculations and integrated tool management. Operators can visualize the bending process before it begins, identify potential issues and make timely adjustments. TecZone Bend also streamlines the process of switching between different parts or production runs, allowing manufacturers to adapt quickly to changing demands.
3. Efficiency
Efficiency is the hallmark of any successful manufacturing line but is even more critical for manufacturers aiming to reshore production. New bending technology and automation not only improve operational performance but also ensure sustainability in a domestic manufacturing environment. Next-level bending efficiency is achieved by adding automation to the process, but the level of automation is easily customized to different operation types, sizes and requirements.
TRUMPF provides a variety of automation options to meet these diverse bending needs, from simple add-on features like ToolMaster to comprehensive solutions like BendMaster, which integrates seamlessly into smart factory setups.
Advanced tool management systems are an easy add-on solution to enhance bending efficiency. ToolMaster optimizes tool setup by providing real-time calculations of expected setup times and facilitating rapid tool changes – often in as little as 12 sec. per tool. This significantly reduces downtime and allows operators to focus on productive tasks, enhancing overall efficiency. ToolMaster can provide data-driven insights into how long setups typically take. This information helps manufacturers identify areas for improvement and optimize their operations further.
Basic automation that can be added to a press brake, such as TRUMPF’s Flex Cell, is another way to ramp up efficiency when needed. Flex Cell automation complements the TruBend 7050 press brake, enabling full or partial automation. This flexibility allows for uninterrupted production after hours or on weekends, making it especially valuable for companies facing labor shortages or urgent order demands. Operators can easily connect the mobile robot cell to the press brake and run the system autonomously for several hours. It is an ideal bending setup for short-staffed companies facing increased productivity needs or looking to bring production of small, simple parts in-house.
For manufacturers dealing with larger or thicker parts, automation such as the BendMaster robotic bending solution enhances efficiency. BendMaster’s robust design minimizes downtime associated with reconfiguration, enabling operators to focus on production rather than setup. BendMaster integrates with Smart Factory concepts and ERP systems, allowing for real-time data sharing and optimized resource allocation. This integration allows for up-to-date visibility into production schedules, inventory levels and resource allocation, which enhances overall operational efficiency.
Coordination helps ensure that production aligns with customer requirements, reduces lead times and improves responsiveness. With ERP integration, manufacturers can push down production requests directly to BendMaster. For example, if the ERP system indicates a need for “50 more pieces,” this request can be communicated to the machine automatically, streamlining the production planning process.
Advanced software tools can track and examine bending machine performance within the production environment. For example, TRUMPF’s Oseon Monitor analyzes the BendMaster performance and collects data on key performance indicators (KPIs) such as machine utilization, downtime and production rates. By monitoring machine performance, manufacturers can identify inefficiencies and adjust future production plans based on real-time data – ensuring resources are allocated effectively.
Reshoring success
Investing in advanced press brake and bending technology is vital for reshoring manufacturing in the United States. New technologies enhance quality, flexibility and efficiency, allowing manufacturers to produce high-quality outputs, adapt to evolving market demands, and increase productivity while reducing labor dependencies. Such advancements are essential – not just for better bending. They strengthen the overall competitiveness of U.S. manufacturing and enable greater bending and fabrication success in a reshored manufacturing landscape.
