Update: New investment – October 2025
We have recently added another press brake to our factory, bringing our total to four. After analysing our On Time In Full (OTIF) performance over the last 12 months, we identified that smaller, high-volume parts could sometimes create delays. Our new 55 Tonne ByBend Smart E will help ease this bottleneck, reduce lead times, and allow more parts to be formed with precision.
Alongside our 80T press, this machine will be used for smaller items and high-volume runs, providing a faster cycle time for the bending process. This will leave our two larger presses for jobs requiring more tonnage. As it’s an electric press, it offers greater efficiency and lower maintenance.
To celebrate this investment, Martin Arnold from Bystronic UK visited us with our new ‘Bystronic Bell’. We have worked closely with Martin for many years, with continued investment in Bystronic lasers and presses; however, this is our first bell!
Martin said: “This is a gift to say thank you for your support and continued business.“
The new press is already making a difference, with our most recent report highlighting a decrease in late formed jobs, keeping parts moving through the workshop more efficiently. Mark Hannon, our Director, and Owen Evans, our Forming Supervisor, are shown with Martin below.
Forming at Midtherm Laser since 2007
Flat bed laser cutting is the foundation of Midtherm Laser, but since 2007 we have also offered forming. Our first press was introduced after we found an increase in requirements from our customers. We now have 4 presses, and forming laser cut parts with precision is a key part of our service.
Our facilities include various press brakes for different applications. Our 225 tonne and 250 tonne presses are suitable for larger, thicker components such as stairs and balustrades up to 4000mm wide. Whereas our smaller 55 tonne and 80 tonne press brakes allows us to fold in high quantity volumes at a fast pace for smaller items such as brackets.
By using the latest bending software, market leading machinery, investment in tooling and highly skilled operators, we can ensure accurate folding, quality and repeatability with every component.
Overview of Our Press Brake Machines
55 Tonne Press – ByBend Smart E 55
- Electric drive solution instead of hydraulic
- Lower expenses for efficient and fast paced bending
- Compact design taking up little space
80 Tonne Press – Xpert 80
- Fast pace bending for smaller items such as brackets
- Internal tooling storage for quick tool changes
- Features electronic top and bottom tool clamping for quicker set up times
225 Tonne Press – Bybend Smart 225
- Newest of the press brakes with state-of-the-art technology and updated computer
- Electronic top tool clamping for a quicker set up time
- Lower power electric consumption
250 Tonne Press – Xpert 250
- Maximum forming length, up to 4000mm
- Suitable for larger, thicker components due to the higher tonnage
- Can use the forklift truck, cranes and additional operators when parts are heavy or awkward
Material Capabilities
There is a lot of variation with the capabilities and limitations of the press brakes. We can form up to 4000mm long on our 250 tonne press, however, not in 15mm thick plate. There are minimum flange length requirements with the tooling and parts can pull, distort and deform. We work with various materials such and mild steel, stainless and aluminium and with each one comes different problems and preferences. We would advise on each job independently when quoting, but here are a few examples;
- Many stainless steel grades can be formed. If the surface is polished, tooling tape or Rolla-V tooling can be used to reduce marking.
- Certain grades of aluminium are more suited to forming as they are softer. Some harder grades can crack when bent over 90°.
- Mild steel generally forms without problems and we can form up to 15mm at certain lengths.
The best way to find out if we can form your part is to send a drawing over to us.
When an enquiry comes in for quoting, we would do the following:
- Assess if the part requires us to form it. Sometimes customers may have the parts flat to source forming themselves.
- Check our limitations to see if it can be formed. We will quote ‘flat only’ if we cannot do them.
- Price to part accordingly and extend the lead time to allow for the bending. Our lead time is currently 10-12 working days due to being very busy. However this is usually 5-6 working days.
- The quote is then sent to the customer to await approval and order confirmation.
Technology and Precision Forming
When programming forming, we use a software called Solid Works. This can create 3D visual of the formed part. It is then checked in BySoft CAM which is a machine specific software which includes all the press brake tooling. The programmers first design the part, then flatten it to create the laser cut pattern. The part can then be checked with the appropriate tools for tonnage and accuracy. The program is then sent to the press brake where each part is bent accurately and with consistent repeatability.
After the parts are formed, they are checked manually to ensure they are formed with precision to the highest standards.
Advances in Precision Forming
Like any machinery, constant updates and advancements in technology are essential. Our recent investment in a Rolla-V tooling bottom die has improved the way we form certain parts. If you watch the video below, you can see how the tooling moves during the forming process.
The Rolla-V tooling is expensive in comparison to the normal tooling but it has significant advantages. It can reduce witness marks that can be created from a still bottom tool. It can reduce holes near the bend lines from pulling. Smaller flanges can be bent on thicker materials and distortion is reduced on patterns on material, such as chequer plate. This type of tooling is tailored to customer needs but has definitely improved the way we form certain parts.
To read more about this tooling, please visit https://rolla-v.com/
Forming Applications and Industries Served
As a sub-contract laser cutter, we supply to various industry sectors. The parts we form have a wide range of applications, from brackets and staircases to fans, with each component tailored to meet specific industry needs. We also cut and form parts for public art installations which can sometimes be more decorative and intricate.
We have a commitment to efficiency and forming parts with precision for every project.
Please Contact Us if you have a job or project you would like us to look at.
Have a watch of our video below to see our forming capabilities here at Midtherm Laser.
