Bending and Brazing Thin Walled Aluminium

Can thin walled aluminium extrusions be formed?

Bending Thin Walled Aluminium is a common challenge we have encountered in our aluminium bending services. Years of experience has shown us just how easily thin walled aluminium sections can be damaged. Cracking, warping or tearing are all potential risks when working with thin material, and finding ways to reduce these risks has been the focus of much of our research and development.


Thin walled Extrusion for tight aluminium bending


We have developed a carefully set up process. One that allows us to bend thin walled sections with very little of damage. Our signature process is surprisingly simple as most solutions tend to be. We have already complete a large number of fantastic projects over the years and results have been outstanding.


Thin Walled aluminium curved to a tight radius (High)



The Solution

We use a combination of specially design tooling and a customized machines to carefully fit the delicate material. Therefore the material is properly supported and guided through the bending process. Finally, once we find the correct set up we track every step to ensure repeatability.

Our intensive quality checking system tracks every issue or error in the bending process. Specifically so that we can quickly address it. While almost all sections will have the same potential issues during testing, individual sections can also bring up unique problems.

Our latest example of this was completing a run of curved aluminium box trims to be used by a prominent aviation company.

Thin walled aluminium curved to tight radius for first aid box


The hurdle of clean, tightly bent thin walled aluminium has been a thorn in the side of aluminium benders for years. In this case we took the challenge and found a new way to approach it. As a result producing a sleek solution to a potentially messy job.



Yet another development on our site is the addition of brazing to our list of services. By bringing on a crew of experience brazing engineers we have allowed for the fusing of very thin aluminium sections without risk of warping.

Brazing is far more delicate that welding and drastically reduces the potential damage that welding can cause on very thin materials. Brazing also creates a nearly seamless fusing between ends


Exceptional 3 Dimensional Bends, impossibly tight radii, and the highest quality final products. These are the aspects that our customers have come to expect when receiving a curved aluminium section from Alubend.

Get in touch and let us show you that we can bend just about anything you can imagine.