Design Assistance

Design Tips for Cost-Effective Manufacturing

Some basic ideas that can help in reducing the overall cost of a part by designing the part to be manufacturing friendly are provided below. For a more in-depth analysis, send us your drawings, or call one of our engineers.

Tube Bending Considerations

CLR- Center Line Radius. Typical CLR is 3x the OD of the tube without mandrels. It is possible to bend on a 1 or 2xD bend, but not without more complex tooling. Tooling costs also increase when comparing a plug mandrel to 3-ball mandrel & wiper die. The tighter the radius, the more tooling required and the more expensive the part.
Use the same CLR for all bends unless prohibited by design restraints.
Straight between bends. Allow 3x the OD of straight for clamping between bends and from the edge of the tube. This reduces the overall cost of part by reducing additional trim operations and increasing the bend rate. Bends closer than 3xD require compound tooling increasing tooling cost and reducing bend rates.

Have Additional Questions?

We’re here to help. Whether you need clarification, design guidance, or want to discuss your project in more detail, our team is ready to assist. Reach out anytime and we’ll make sure you get the support you need.

Other Considerations

Beyond the basics, there are additional factors that can impact the performance, cost, and manufacturability of your part. Explore these key considerations to help ensure your design is efficient, practical, and production-ready.