Panel Benders Vs. Press Brakes - Which Is Better And Why?

How Are Panel Benders Different From Press Brakes?

While the press brake has been the go-to bending machine for many years, depending on the part, the panel bender can have several advantages over the traditional press brake.

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Machine Set Up

The most apparent difference between a press brake and a panel bender lies in the physical method of bending sheet metal. For a traditional hydraulic press brake, clamps are employed to secure the hangers that hold the upper punch and the lower riser, which in turn holds the V-die. The punch descends onto the sheet metal to form the bend into the V-die, operated via a foot pedal. V-dies come in different sizes, aligned with sheet thickness and required bend radii and angles. Specific jobs may demand various specialty dies and punches, like a gooseneck for u-profiles or a narrow punch for limited spaces during the final bend.

However, investing in diverse tooling can be costly and may hinder a project's budget. Additionally, press brake tooling needs periodic replacement due to wear and requires significant labor and time to switch out for different parts.

A panel bender operates differently, often utilizing automation. In a panel bender, the sheet is securely held by the counter blade and blank holder. The machine employs upper and lower universal bending blades that apply lateral force to fold the sheet metal. The universal counter blade, blank holder, and bending blades adapt to various material sizes and thicknesses, eliminating the need to change tooling and minimizing production downtime between jobs.

Production Efficiencies

Besides the tooling benefits, panel benders surpass traditional press brakes in terms of speed, repeatability, and consistency.

Although both machines can utilize CNC (computer numerical control) technology, a press brake requires manual manipulation of the sheet metal for each bend. Handling large sheets can be challenging for operators or necessitate multiple people, affecting efficiency and quality due to operator fatigue.

On the other hand, a panel bender features a part manipulator that moves the sheet metal. Once the sheet is positioned against the locating device, the entire piece is formed without further operator intervention. Intelligent sensors measure material thickness, size, and environmental temperature, adjusting the panel bender tooling accordingly to prevent waste, mistakes, and inefficiencies.

A panel bender can bend a part two to three times faster than a press brake with superior consistency. For instance, the Salvagnini P4 Panel Bender averages 17 bends per minute. This level of automation can even accommodate lights-out operation for meeting tight deadlines.

Contact us to discuss your requirements of stainless steel panel bender. Our experienced sales team can help you identify the options that best suit your needs.

Quality

One issue that arises with press brakes that is eliminated with panel benders is back bending. Back bending results from the material lagging behind the press while the form is taking place, which generally results in a whipping motion as the material tries to catch up with the press. Back bending is more common in very large panels where the operator cannot keep up with the press’s speed as the material is manually raised during the actual forming process. The result is a slight reverse kink or bend at the die edge. Another instance where back bending can occur is when the material hits the back of the form tooling before the bend is complete. With the panel bender, the material mass lies flat on the table and does not have to follow the press action during the bending operation, thereby eliminating the risk of back bending.

In addition, the panel bender has unparalleled accuracy and repeatability numbers. The panel bender’s integrated advanced sensors measure the blank, including material thickness, for precise placement and bending. The sensors also detect any deformations caused by variations in temperature. The collected data is used to instantly calculate the correct force required to bend the sheet metal. From the inside bend line to the inside bend line, the accuracy is +/- .008″ on the overall panel dimension. The repeatability of the panel bender is +/- .004″.

What is a good part for a panel bender?

Not surprisingly, a good part for a panel bender is…a panel! There are many projects with panels that are excellent candidates for using a panel bender, including:

• Cabinet components
• Enclosures
• Appliance components
• Lighting fixtures
• Architectural panels
• And more

The size of the panel will depend on the limitations of the specific panel bender being used. To provide a reference, the ideal part dimensions for the Salvagnini Panel Benders used by Estes are:

• Up to 11 gauge steel, 14 gauge stainless steel, .150″ aluminum
• Up to 85.8″ bend length
• Up to 62.9″ blank width
• Up to 98.4″ blank diagonal
• Up to 6.5″ bend height

Even though a panel bender offers ease of setup, greater operating efficiencies, and high-quality output, there are a number of parts that fall outside the criteria and are better suited for fabrication using a press brake.

When it comes to high-quality metal fabrication, both the panel bender and press brake have a place. The decision as to which to use will depend on the type and size of the project.

Contact Estes

If you have questions or are looking for a partner with proven experience in sheet metal fabrication, Estes has the experience to deliver. Contact us today to get started!

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