Custom TRUMPF Type Radius Forming Tool for 10 mm Thick Plate – Multi-Radius One-Step Forming

Key Features

• Custom TRUMPF Type press brake forming tool
• Designed for 10 mm thick plate forming
• Forms three coordinated radii in one operation
• Includes two side radii and one large central radius
• One-step forming reduces repeated bending and repositioning
• Tool geometry is designed with material springback compensation
• High-strength tooling structure for large forming loads
• Matching upper and lower forming profiles
• Suitable for complex curved and profiled sheet metal parts
• Designed according to the customer's finished workpiece geometry
• Manufactured from 42CrMo alloy steel
• Heat treated for strength, wear resistance, and dimensional stability
• Press brake mounting structure can be customized
• Available in TRUMPF Type, WILA Type, LVD Type, AMADA Type, BYSTRONIC Type, and other mounting configurations
• Free press brake tooling design service available
• Tool height, width, working length, radius, and mounting interface can be customized

Technical Specifications

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Complex Multi-Radius Forming in One Operation

The defining feature of this tooling set is that it forms three different curved sections in a single press brake operation.

The finished workpiece includes:

• Two side curved transitions
• One larger central radius
• Two extended side flanges

Instead of producing these geometries through several independent bending operations, the upper and lower tooling profiles are designed to form the complete section at once.

This can help reduce:

• Multiple bending steps
• Repositioning errors
• Accumulated dimensional deviation
• Operator dependency
• Cycle time for complex profiles

For parts with demanding cross-sectional geometry, a dedicated forming tool can provide much more consistent results than attempting to reproduce the same shape through multiple conventional bends.

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Designed Specifically for 10 mm Thick Plate

This tooling set is used for 10 mm thick plate, which creates substantially greater forming loads than thin sheet metal.

For this type of application, the challenge is not simply producing the correct radius.

The tooling must simultaneously provide:

Sufficient Structural Strength + Accurate Forming Geometry + Stable Load Transfer

The upper and lower tool bodies therefore require substantial cross-sections to withstand the forming force without excessive deformation.

For thick-plate forming applications, the complete tooling design must consider:

• Material thickness
• Material tensile strength
• Forming length
• Required finished radii
• Press brake capacity
• Tooling strength
• Stress concentration
• Machine mounting structure

This is why complex thick-plate forming tools are normally engineered as a complete tooling system rather than selected from a standard punch and die catalog.

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Springback Compensation for Accurate Final Geometry

One of the most difficult aspects of this application is material springback.

After forming pressure is released, the plate naturally tends to recover part of its original shape. For 10 mm thick material, even a relatively small springback error can create a significant deviation in the final radius and overall workpiece profile.

For this reason, the tooling geometry cannot simply reproduce the nominal finished part shape.

The design must consider:

• Material grade
• Material thickness
• Elastic recovery
• Required final radius
• Forming pressure
• Upper and lower tool interaction

Appropriate over-forming and geometry compensation can be incorporated into the tool design so that, after springback occurs, the finished workpiece approaches the required final dimensions.

TRUMPF itself describes complex special tools as being developed around the component and process, with material, shape, and machine parameters coordinated together.

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Radius Forming with Matched Upper and Lower Tools

Unlike conventional air bending, this application uses a matched upper and lower forming profile.

The workpiece is progressively pressed between the two tool surfaces until the plate conforms to the required profile.

This forming method is particularly suitable for:

• Large-radius components
• Multiple-radius sections
• Thick plate profiles
• Special curved cross-sections
• Parts requiring repeatable profile geometry

TRUMPF also identifies radius forming tools as a special-tool category in which the final radius is produced through a defined relationship between the upper and lower forming tools.

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High Tooling Strength for Heavy Forming Loads

Forming a 10 mm thick plate across multiple radii generates very high loads on the tooling.

The tooling structure must therefore be designed with sufficient material around the working areas to resist:

• Bending stress
• Localized compression
• Tool deflection
• Permanent deformation
• Repeated industrial loading

The large upper and lower tool bodies shown in this design are not oversized unnecessarily. Their dimensions are part of the load-bearing structure required for reliable thick-plate forming.

Actual forming force should always be evaluated according to material grade, thickness, forming length, radius geometry, and press brake capacity before production.

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Custom Tooling Designed from the Finished Workpiece

This tooling was developed around the customer's required finished part, rather than around an existing standard punch profile.

This is the core principle behind WYS custom press brake tooling:

Customer Workpiece Drawing
→ Forming Process Analysis
→ Tool Geometry Design
→ Springback & Strength Evaluation
→ Tool Manufacturing
→ Finished Workpiece Forming

Customers can provide:

• 2D workpiece drawings
• 3D models
• Material grade
• Material thickness
• Required tolerances
• Press brake model
• Existing tooling system
• Production quantity

Our engineering team can then provide a free press brake tooling design proposal based on the actual bending and forming requirements.

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Fully Customizable Mounting and Tool Geometry

The tooling shown here uses a TRUMPF Type mounting structure, but the forming geometry itself is not limited to this tooling system.

We can manufacture similar custom forming tools with:

• TRUMPF Type
• WILA Type
• LVD Type
• AMADA Type
• BYSTRONIC Type
• Other press brake mounting systems

Customization can include:

• Tool height
• Tool width
• Working length
• Upper and lower tool geometry
• Radius size
• Number of forming radii
• Clearance structures
• Mounting interface
• Segmented construction
• Reinforced load-bearing sections

This means the tooling shown on this page represents one custom forming solution, not the limit of our manufacturing capability.