Sheet Metal Bending vs. Cutting: Which Process is Right for Your Project?

Sheet metal uses different processes to render the sheet useful for various projects. In DIY uses, you can choose how you want to process the metal, but in industries like construction, automotive, aerospace, and others, every process is chosen carefully based on certain factors.

Two methods that are quite popular in sheet metal processing are sheet metal bending and sheet metal cutting. While these two processes are fundamentally different, you might need to choose between them sometimes.

Thus, this blog explores the differences between sheet metal cutting and bending, which machinery is used, and which method is right for your project.

What is Sheet Metal Processing?

Both sheet metal bending and cutting come under the umbrella of sheet metal processing. Thus, you should know about this concept.

Sheet metal processing is the method of transforming sheet metal into desired shapes by processing it as per the project’s need. It includes sheet metal cutting, shearing, sawing, punching, notching, welding, bending, etc. These techniques are employed exclusively or with each other, sometimes to serve a distinct purpose. All these processes are important, but two of the most vital ones are sheet metal bending and cutting. Both are different, serve particular purposes, and use specialized equipment to achieve the desired result.

What is Sheet Metal Bending?

Sheet metal bending refers to deforming metal into a certain shape without cutting or welding it. Instead, the force is applied, and the metal is bent at a certain angle to curve it. For example, to make a square, the sheet metal is bent at right angles thrice to create the shape. Projects requiring structural integrity and precision rely on sheet metal bending.

Methods of Sheet Metal Bending

There are different sheet metal bending methods. Check these out:

Air Bending: In this method, a punch and die set is used, and the punch forces the metal to bend at different angles without touching the bottom of the die. It allows metal sheets to be bent at multiple angles per the requirement.

Bottoming: In this method, the die is designed to create precise angles every time. The punch forces the sheet metal completely into the die.

Roll Bending: A couple of rollers are used in this method. The metal sheet passes between them and is bent as per the need.

V-Bending: In this method, a V-shaped die is used, and the punch presses the sheet metal into it, creating a perfect angle.

Advantages of Metal Bending

Here are the advantages of metal bending:

• It maintains material strength which is often lost in cutting. The edges might get frayed or burred in the process, which affects the material’s strength.
• Metal bending allows for creating complex designs and angles that welding can’t offer.
• There is very little material waste, as the metal is not detached from the sheet.
• In the case of large-production runs, metal bending proves to be very cost-effective.

Use Cases of Sheet Metal Bending

• Metal bending is preferred when working with ductile metals like aluminum, steel, or brass, which are easy to deform.
• Projects that require structural integrity should opt for metal bending, as cutting impacts the metal’s strength.
• When a smooth and aesthetic finish is required, metal bending should be chosen over metal cutting.

What is Sheet Metal Cutting?

Sheet metal cutting involves removing metal from a sheet to make it useful for further processing. It includes cutting down larger sheets into manageable sizes or specific shapes for a project.

Methods of Sheet Metal Cutting

Here are the different sheet metal cutting methods:

Laser Cutting: It uses a high-powered laser to cut sheet metal. The technique is popular for its precision and ability to cut complex designs in the sheet.

Plasma Cutting: For thicker materials, a plasma torch is used.

Water-jet Cutting: Water is mixed up with abrasive materials in water-jet cutting. It cuts the sheet metal when shot through the metal with an unnatural force. This method is preferred to avoid heat damage to the metal.

Shearing: Shearing is the process of cutting metals with a shear force that doesn’t leave any burrs or chipped edges.

Advantages of Sheet Metal Cutting

Here are the advantages of sheet metal cutting:

• Using advanced technologies has rendered sheet metal cutting a very accurate process for cutting metal.
• With CNC and laser-cutting machines, even the most complex shapes can be cut with considerable ease.
• The multiple cutting methods discussed above can cut various material thicknesses.

Use Cases of Sheet Metal Cutting

• When detailed cutouts are required, metal bending doesn’t help, and metal cutting is used.
• It is used to cut larger sheets into smaller ones.
• Metal cutting is used when using thick and hard materials that cannot be bent easily.

Sheet Metal Bending Machine vs. Sheet Metal Cutting Machine

It is not justified to compare the machines in these two operations, considering they perform two very different tasks.

Sheet metal bending machines include press brakes, roll benders, folding machines, etc., while sheet metal cutting machines include laser cutting machines, metal shears, plasma cutting machines, etc.

Choosing between the two methods is uncommon, but if you are facing a dilemma, visit us at New Mexico Metals LLC. We will understand your project and then guide you to choose the right method.

Final Words

Both sheet metal bending and cutting are essential in sheet metal processing. Ideally, you shouldn’t have to choose between them, but if you must, consult an expert who can assist you.

New Mexico Metal LLC is the best metal service provider in Albuquerque. We offer multiple services and line items and can help you anytime. Whether it is sheet metal bending or cutting, we house the most advanced machines and thus provide exceptional sheet metal processing services.

For details, visit us at your earliest convenience.