Blog | | by Patrick

Bend Simulation Optimizes Manufacturing Process

Advantages of a Bend Simulation

Bend simulation has become an indispensable tool in modern sheet metal fabrication. In the past, the feasibility of a sheet metal part regarding the bending process was assessed through technical drawings and the spatial imagination of experienced machine operators in collaboration with production planning.

Today, however, critical aspects of the bending process, such as avoiding collisions of the workpiece with the lower or upper tools, as well as other attachments of the executing machine, can be simulated with just a few clicks.

Collision Check

When bending sheet metal parts, it is crucial that the part does not collide with the machine or the beam press. This can be checked and ruled out through the precise selection of tools and the machine in the simulation. Modern simulation software enables detailed analysis, thus preventing potential damage to the machine and the part.

Bending Sequence

The geometry of the part and its proportionality significantly dictate the framework conditions for the bending process. The bending sequence also depends on factors such as tool selection, collision avoidance, and economic considerations. Through bend simulation, these aspects can be checked in advance, and the bending program or the design of the part can be adjusted accordingly. For instance, collisions can be avoided by adjusting the bending sequence or using special tools. Additionally, efficiency can be increased by simultaneously bending legs with collinear bend lines.

General Bendability

To realize the bending of a sheet metal part, fundamental parameters must be observed. For example, legs must have a minimum length based on the sheet thickness and the tool pairing. Moreover, cutouts must not be positioned too close to the bending zone, as they would otherwise deform. Many of these parameters can also be found on our homepage under Sheet Metal Guide.

Digital Feasibility Analysis with Optimate

With our Optimate feasibility analysis, we can digitize the relevant sheet bending rules and check them at the push of a button. This ensures the consistent adherence to the fundamental principles of sheet metal bending technology.


The points outlined impressively demonstrate the indispensable advantages of a bend simulation. In particular, the significant reduction of rejected parts and the minimization of design errors contribute substantially to efficiency enhancement. Furthermore, support through bend simulations is of immense importance in the context of the current skilled labor shortage, as it reduces the need for experienced professionals while ensuring the quality and precision of the manufactured parts.

Written by

Patrick Klein

Sales Manager

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