---

---

Custom press brake tooling offers a powerful solution to avoid bottleneck issues. Special forming tools can cut the number of bends and handling, reducing machine time and setup which boosts throughput and eases production flow.

What Causes Bottlenecks?

The buffering effect from manufacturing cell bottlenecks slow downstream flow as machines wait for one another – resulting in downtime and wasted hours. Press brakes are often the culprit, as they are one of the slowest processes in manufacturing cells and in the fabrication process in general. A single turret punch or laser can feed three to four press brakes at once. Many shops respond to this gap by simply adding more press brakes to handle the incredible volume.

This approach may overlook the full cost of operating a press brake if focusing only on the shop rate and not on the total cost. When factoring in floor space, salaries, maintenance, depreciation, and energy use, hourly costs can exceed $500 and are trending higher with inflation and taxes.

Custom Press Brake Tooling Creates Significant Savings

Most press brakes operate at about 50% efficiency, causing shops to overspend for underused equipment. For instance, a $500 loaded shop rate over 252 days equals $1,008,000 per machine annually. Reducing bends and handling by using efficient tools can yield significant savings, especially for shops running multiple brakes around the clock. It’s crucial to find creative ways to minimize handling and maximize press brake output.

How Custom Press Brake Tooling Avoids Bottlenecks

When fabricating a part in a press brake, there are a number of scenarios where custom press brake tooling can improve process speed and efficiency. Here are some examples of how custom tooling can help streamline operations:

1. Bend a part with an offset in a single hit versus two or three bends (provided your machine has the tonnage and open/close capabilities to make fewer hits).
2. Run a part without flipping the sheet.
3. Create a more ergonomic method of bending.
4. Integrate engraving, embossing, and other turret-specific operations into the press brake as a single-stage bending operation.
5. Combine hardware installation and bending.
6. Form large radii in one hit instead of bumping.
7. Form a hinge instead of spot-welding it.
8. Combine a bend and hem in one operation.
9. Form rods with the press brake, not a rod bender.

On-site Fabrication Specialists Available

Not sure whether custom tools can improve your efficiency? Mate Precision Technologies offers on-site Fabrication Specialists to analyze your workflow and recommend solutions. Our experienced team focuses on eliminating waste, reducing non-value-added operations, and boosting safety and throughput – all to help your press brake department continually improve.

Make your press brake department shine. Contact your Mate Fabrication Specialist for an on-site visit.