Merge Manufacturing LLC

For thinnner walled tubes, tighter radii, or larger solid materials we use rotary draw bending.
This style of bending has more tooling components, and their sole purpose is to increase the support of the tube wall so that during bending it doesn't distort or buckle. This style of bending can allow for bend radii of down to 1x the material diameter in tubes, provided the material has high enough elongation. Basic draw bend dies consist of the die, clamps, and sliding rear supports. As bend radius or wall thickness decreases, we add a mandrel inside of the tube to support the tube wall on the outside of the bend. This will reduce or eliminate the flattening that happens on the outside of a tube as it is bent. As the radius or wall thickness continues to decrease the mandrel is changed from the simple plug type, to one with one, two, three, or more articulating balls. The ball mandrel provides even more support to the outside of the tube during bending. In addition to a ball mandrel, a wiper die may be added to pull out the wrinkling that occurs on the inside
of the bend.

We strive to implement tools and processes to maximize efficiency. We are constantly evolving and streamlining processes to maximize efficiency. Our lean assembly processes consist of labor-saving flow of materials and floor layout, inspection at the appropriate intervals, and proper attention to detail. Set up for fast change overs and minimal downtime, we are able to assemble and package product more cost effectively by identifying, targeting and innovating the slowest steps.

Thanks to the advanced bending equipment we use and our ability to quickly design and fabricate custom tooling; we can bend channels, oval tubing, or custom extrusions in addition to traditional round, square, and rectangular tubes and solid materials. We have a large supply of stock tubing and pipes for all applications, and our close relationships with our material suppliers allows us to order just about any material for any job.

We are here to answer any questions you may have about Merge Manufacturing. Please do not hesitate to reach out and learn more about our capabilities. Tell us about your vision and we can work with you to create your custom project. If you have a regularly manufactured product line and would like to discuss how Merge Manufacturing might be able to reduce costs and improve production time, let us know.