Automated Sheet Metal Bending: How You Can Transform Your Fabrication Process with Simulation and Strategy

Why Automated Sheet Metal Bending Will Help You Change the Game

You should be considering automated sheet metal bending to improve your fabrication process. At first glance, bending sheet metal might seem like one of the easier tasks on the shop floor. Clamp, bend, repeat—right? 

Not quite. 

In reality, bending is deceptively complex. Firstly, variables like material thickness, flange length, part geometry, and even gravity all influence the outcome. Moreover, when you add robotic automation to the mix, and the stakes get higher. 

That’s why at Space Age Electronics, when we committed to automated sheet metal bending, we knew we needed more than good machinery. We needed a strategy that would bring consistency, efficiency, and adaptability to every job—whether we were forming basic boxes or complex, multi-flange brackets.

Simulation: The Secret Weapon for Bending Success

While the AMADA EG 6013 on its own provides tangible benefits, our real breakthrough came when we started simulating each robotic bending cycle before hitting “go.”

With digital simulation, we tested gripper placements, bend sequences, tool clearances, and even rotation strategies. Then, we ran countless “what-if” scenarios—virtually—before cutting a single sheet.

This gave us huge advantages:

• Fewer errors and reworks
• Optimized tooling combinations
• Clear paths for continuous part handling

Simulation didn’t just help us avoid problems—it gave us the power to engineer better bends from the start.

And the best part? We didn’t have to rely on trial and error. As a result, we saved hours per job setup.

Understanding the Automated Sheet Metal Bending: Geometry Meets Gravity

One of the biggest insights we gained was this: gravity matters—a lot.

Large, thin blanks tend to sag under their own weight. Therefore, if your first bend doesn’t lock in rigidity, the rest of the cycle turns into a balancing act.

So, we adjusted our sequence.

By consistently starting with the longest flange, we added structural support immediately. In fact, this lets the robot maintain a steady grip—and its “home” position—through the rest of the bends.

No repositioning. No misalignment. No hiccups.

That one strategic tweak made our robotic bending cycles faster and more reliable. In effect, it helped us scale up to larger parts with complex forms.

Repositioning Kills Time. So, We Eliminated It.

If you’ve ever watched a robotic cell struggle through multiple repositioning moves, you know it’s a time sink.

We knew our path forward meant cutting down those moves.

Our engineers focused heavily on bend sequence optimization. Accordingly, they designed strategies that allowed the robot to grip once—and finish all bends in that single hold.

This called for:

• Smarter gripper designs
• Tooling that allowed multiple flange geometries
• Careful simulation of angle and approach paths

Today, most of our robotic bends happen without any repositioning. Even on complex parts, we hold the component steady, complete all bends, and move on. That’s saved us significant time while improving accuracy across the board.

What Automated Sheet Metal Bending Changed for Us

These changes didn’t just upgrade one machine. They upgraded our entire workflow.

Here’s what we’ve gained from automated sheet metal bending:

• Shorter cycle times: With fewer stops and starts, we produce more in less time.
• Consistent part quality: Our tolerance holds are tighter than ever, especially across large batch runs.
• Increased capacity: We now take on more complex jobs—without sacrificing speed or quality.

We also freed up skilled operators to focus on more engaging tasks, from simulation programming to process innovation.

And perhaps most importantly, we laid the groundwork for future automation phases—including the upstream blanking optimizations we’ll discuss in Part 4.

A Quick Look at the Bigger Picture

Our success with automated sheet metal bending is part of a larger strategy.

Each automation stage—from welding to bending to blanking—builds on the last. We’re not just replacing manual labor with robots. We’re building a smarter, more resilient manufacturing system that empowers people, adapts quickly, and delivers consistent quality at scale.

What’s Coming Next?

In Part 4, we’ll explore how optimizing blanking and part removal helped us accelerate upstream processes and reduce material waste.

Every bend, every blank, every weld—it’s all connected. And when you align those processes under one automation strategy, the results are exponential.

Stay tuned!