Precision tube bending for complex assemblies
Bauer delivers precision tube bending services that always meet specs and deadlines, keeping even the most complex projects on schedule.
Fast quotes
Design for Manufacturing support
Prototype to production
At-a-Glance Specs
Take a quick look at our standard bending ranges. If you don’t see something you’re looking for, we may still be able to help. Send the print. We’ll review and advise.
Outside diameter (OD)
Tube: 0.25” to 5.00”
Solid bar: up to 3.50”
Wall thickness
0.028″ wall to 0.250″ wall
Bend method
CNC mandrel bending
Rotary draw
Press bending
Push bending
Bend angle accuracy
±.3° typical
Bend radius (CLR)
Centerline radii up to 24”
Materials
Mild steel
Chromoly
Stainless steel
Aluminum
Tube Shapes
Round
Square
Rectangular
Oval
Extrusions
Volumes
Prototype, preproduction, production
File formats
PDF for prints, STEP, IGES, Parasolid, SolidWorks [.sldprt, .sldasm, .slddrw]
What you get by bending with Bauer
Faster launches, fewer surprises
Shorten the path from prototype to production with DFM feedback up front, rapid quoting and dependable schedules that keep launches on track.
Complex geometries, comprehensive services
Tight radii, multi-radius parts, compound bends and coils, so you can consolidate suppliers and simplify builds.
Lower total cost, not just piece price
Leverage in-house fixturing and a deep bend die library to reduce tooling costs, avoid long tool lead times and protect early production quality.
IN-HOUSE Capabilities
MANDREL AND TIGHT-RADIUS BENDING
- 0.25″ – 5.00″ OD
- Tight radii and consistent geometry for complex assemblies
- Prototype through production with repeatability
PUSH BENDING
- Best fit for large radii and specific geometries
- Also used for long sweeps and stable arcs
SINGLE, DOUBLE- OR TRIPLE-STACK HEADS
- Multi-radius bends in one setup where feasible
- Reduces changeovers while holding geometry across radii
- Supports higher throughput and more stable scheduling
COMPOUND BENDS AND COMPLEX PART SHAPES
- Complex geometries evaluated with DFM and simulation as needed
- Handles multi-plane bends and challenging assemblies without distortion surprises
- Validated early so production runs stay consistent
IN-HOUSE FIXTURING AND TOOLING SUPPORT
- Check fixtures designed for your geometry and downstream install needs
- Faster ramp-up with more predictable repeatability
- Reduces reliance on outside vendors and tooling delays
See our shop floor
Have a look inside our facility to see how Bauer provides precision and reliability at every level.
DFM guidelines (save time + cost)
The fastest way to reduce lead time and rework is to make bending and welding manufacturable from day one. Send your model early and Bauer will flag risk areas and recommend changes that protect quality and cost.
- Bending: Preferred radii and die availability (avoid custom tooling when possible)
- Welding: Joint access and fixturing clearances (design for repeatable welds)
Complex assemblies, precision bending
Look at some of our complex tube assemblies and see what Bauer’s bending capabilities can do for you.
Multi-radius tube assembly
Triple-stack radii plus welded brackets
Tight-radius mandrel bend
Thin-wall control plus ovality risk managed
Bend plus laser-cut tube component
Cut features aligned to bend orientation
Welded tube frame/subassembly
Robotic welding for throughput and consistency
Prototype-to-production program part
DFM and fixture strategy to scale cleanly
Hear it from our customers
“They’re saving at least $15 on a piece cost and hundreds of thousands on initial tooling.”
Brad
Engineering program manager
$150k
Tooling cost savings
“We’ve never had a quality issue, never had a delivery issue.”
Stephen
Commodity manager
National backup power generation manufacturer
Zero
Quality or delivery issues reported
“If there’s any exceptions or they’re suggesting an alternative material or they’re requesting additional tolerance on something, they’re making sure they do their front-end work, which is good to see.”
Alex
Procurement manager
Global furniture manufacturer
On time
Three-week delays avoided
FAQs
These are the questions we hear most from engineers and sourcing teams. If your question isn’t answered here, please reach out to us for more information.
Yes, our team can handle initial prototyping to full-scale production.
Yes. Bauer in-house capabilities support everything you need to deliver complex weldment prototypes. You can move from prototype to production without switching suppliers midstream.
Integrated processes, tooling templates and real-time communication, engineer to engineer.
.PDF and STEP are preferred, but we can work with most major formats.
Absolutely. Every quote includes manufacturability insights, and we’ll redline files with recommendations.
Expect quote responses within three to five business days. Prototype lead times are often within two to three weeks. Production timelines vary based on part complexity, volume and material.
Yes, our in-house tool shop can produce all check and weld fixtures.
From complex
specs to premium assemblies
Whether you’re recovering from a supplier failure or gearing up for a new launch, Bauer will help you get it done right — fast.
