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Engineering & Development of a Hand Bender for the Motorcycle Industry

Hand Operated Tube Bending Fixture 1
Hand Operated Tube Bending Fixture 2
Hand Operated Tube Bending Fixture 3

Engineering & Development of a Hand Bender for the Motorcycle Industry

The custom machine highlighted here was designed, engineered, and fabricated as a hand bender for a manufacturer of motorcycles. At Excel Machine & Tool, Inc. we understand that automated systems are not always the most cost effective solution. This customer was forming tube assemblies in low volume, which made a manual option the most viable.

The fixture we engineered featured simple operation, and was fabricated with robust features. To form the part, the straight tube assembly is clamped into the fixture, the operator then manually rotates the tooling in a specified sequence, bending the tube in 9 different locations.

The hand bender consisted of a fixture stand that was fabricated from 2" x 2" angle iron, and a hot rolled steel base, and precision tooling that could accommodate the 3/16" O.D. tubing. The tooling was machined from heat treated 1018 and hot rolled steel, as well as A2, and S7 tool steel. Many components were primed and painted, and everything was fully inspected for dimensional accuracy. We completed the entire project in just 5 weeks.

To learn more about this project, see the table below or contact us directly.

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Highlights of this Engineering, Design, & Fabrication Project

Product NameHand Bender
Product DescriptionA straight tube assembly is clamped in the fixture. Operator manually rotates the tooling in a specified sequence to bend the tube in 9 different locations.
Engineering, Design, & Fabrication
 Capabilities Applied/Processes
Primary:
Engineering/Design
Fabrication
  • CNC Milling
  • Welding
  • Grinding
Secondary:
Priming
Painting
&Assembly
Heat Treating
Equipment Used to Manufacture Part
CNC Mill
Manual Mills
Manual Drills
Manual Grinders
Automatic Grinders
Manual Lathe
Hand Tools
Gage Pins
Gage Blocks
Height Gages
Micrometers
Dial Caliper
Overall Part Dimensions3/16 diameter tubing with 9 bends
Bending Tolerances±1.5mm
Material Used
Fixture Stand
  • Angle Iron
    • Width: 2"
    • Height: 2"
    • Thickness: 3/16"
Hot Rolled Steel Base Plate
  • Thickness: 5/8"
Fuel Tube Assembly
  • Steel Tubing
    • OD: 3/16"
    • Thickness: 0.028"
Tooling: made from a combination of material
  • Hot rolled steel
  • 1018 steel
  • A2 Tool steel
  • S7 Tool Steel
  • All tooling subject to wear is heat treated for longevity
Material FinishMachine Base: Primed and Painted
In process testing/inspection performedDimensional Inspection, Gage Inspection, Functionality Testing
Industry for Use
Automotive Industry
Appliance Industry
Agricultural Industry
Aerospace Industry
Medical Industry
Volume1
Delivery/Turnaround Time5 weeks
Delivery LocationNew Albany, Indiana
Standards MetCustomer Specifications, CAD Drawing

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