Press brake folding is a common sheet metal process used to create accurate bends, angles and formed sections. It turns a flat metal sheet into a component that is ready for welding, assembly or installation.
The process offers greater accuracy and consistency than manual bending. As a result, it works well for everything from one-off bespoke parts to repeat components.
How does a press brake work?
A press brake uses a punch and die to apply controlled force to a sheet of metal. The machine pushes the material into the required shape, creating a straight and accurate bend.
Different tools can produce various angles and profiles. The operator also controls the position and depth of each bend to achieve the required dimensions.
However, several factors affect how the metal will fold. These include its grade, thickness, bend length and the angle required. The direction of the material grain may also influence the finished result.
Which materials can be folded?
Press brake folding suits many commonly used sheet metals, including mild steel, stainless steel, aluminium, brass and copper.
Each material behaves differently under pressure. For example, stainless steel usually needs more force than mild steel of the same thickness. Aluminium requires careful handling because certain grades can crack if the bend radius is too tight.
Choosing the correct tooling and bend allowance helps produce an accurate finished component.
What is press brake folding used for?
Sheet metal folding forms parts for many different industries and applications. Common examples include:
• Trays, channels and angles
• Brackets and support sections
• Machine guards and covers
• Panels and enclosures
• Flashings and folded sections
• Food-processing equipment
• Architectural metalwork
• Bespoke components and assemblies
A folded component can often replace several separate pieces of metal. This reduces the amount of welding required and can create a neater, stronger result. It may also shorten fabrication and assembly time.
Accurate in-house sheet metal folding
At Acorn Engineering & Fabrications, we carry out press brake folding in-house at our Blaydon workshop.
Our 150-tonne, 4.1-metre press brake allows us to form a wide range of sheet metal components. Keeping this process in-house also helps us coordinate cutting, folding, welding and finishing within one workshop.
We can work from customer drawings, existing components or measurements taken from site. Where a finished design is not yet available, we can also help develop a practical fabrication solution.
Press brake folding in the North East
Accurate folding helps components fit together correctly during fabrication and installation. It also improves consistency across repeat parts and reduces the need for adjustment later.
Whether the job involves a single replacement bracket, a folded tray or a larger fabricated assembly, the correct folding method will depend on the material, dimensions and intended use.
Acorn Engineering and Fabrications provides press brake folding and sheet metal fabrication for customers across the North East of England.
In food and beverage manufacturing, equipment must do more than simply perform its intended function. It also needs to withstand regular cleaning, resist corrosion and be designed without unnecessary areas where product or debris could collect.
At Acorn Engineering and Fabrications, we provide bespoke stainless steel fabrication in North East England, working with food and beverage manufacturers to produce practical equipment and resolve production problems.
For this reason, manufacturers throughout the industry rely on stainless steel. However, selecting the correct material is only part of the process. The design, fabrication method and quality of the finished surfaces are equally important.
Why is stainless steel used in food manufacturing?
Stainless steel is durable, corrosion-resistant and relatively easy to clean. Unlike painted or coated mild steel, there is no surface coating to chip or flake during normal use.
These properties make it suitable for many production and washdown environments. For example, fabricators use stainless steel to manufacture items such as:
• Machine guards and covers
• Trays, chutes and hoppers
• Worktables and preparation surfaces
• Pipework supports and brackets
• Frames and equipment stands
• Drip trays and catchment units
• Access platforms and steps
• Bespoke modifications to existing machinery
The most suitable design and material grade will depend on where the equipment is being installed, what it will come into contact with and how it will be cleaned.
Choosing between 304 and 316 stainless steel
Two of the most commonly used grades are 304 and 316 stainless steel.
Manufacturers commonly use Grade 304 for general food production equipment, work surfaces, guards and other components. It offers good corrosion resistance and is suitable for many indoor processing environments.
Grade 316 contains molybdenum, which provides greater resistance to corrosion. Fabricators may select it where equipment faces exposure to salt, more aggressive cleaning chemicals or particularly demanding processing conditions.
Using a more expensive grade is not automatically better. Base the correct choice on the application, operating environment and cleaning regime. Understanding how the finished item will be used helps avoid unnecessary costs while ensuring the material is suitable for the job.
Hygienic design involves more than the material
Simply manufacturing something from stainless steel does not automatically make it hygienic.
The design should also consider the shape of the equipment, its accessibility for cleaning and whether there are crevices or awkward areas where moisture and debris could collect.
Depending on the application, this may involve:
• Reducing unnecessary joints and overlapping sections
• Avoiding inaccessible gaps
• Using continuous welds where required
• Dressing and polishing welded areas
• Creating falls to prevent standing liquid
• Providing access for inspection and cleaning
• Minimising sharp corners and difficult-to-reach surfaces
These considerations are particularly important near open food production areas.
Surface finish and fabrication quality
The required finish will depend on the intended use of the equipment. Some components may only need a clean, consistent workshop finish, while exposed or hygienic surfaces may require welds to be fully dressed and polished.
In addition, fabricators must take care throughout the process to avoid contaminating stainless steel with particles from mild steel. Separate tools, suitable abrasives and careful handling help maintain the appearance and corrosion resistance of the finished product.
Accurate cutting and forming also make a difference. Well-planned folds can reduce the number of separate components and welded joints required, resulting in cleaner equipment that is easier to maintain.
Fabricating a practical solution
Food and beverage manufacturers do not always approach us with a completed drawing. In many cases, the starting point is a problem on the production floor.
An existing component may be difficult to clean, a guard may need modifying, or new equipment may have created an access or handling issue. Production changes can also mean that something which previously worked well is no longer suitable.
This is where experience of bespoke fabrication becomes particularly valuable.
By looking at how the area operates in practice, we can help develop a solution that considers:
• The available space
• Operator access
• Cleaning requirements
• Strength and durability
• Existing machinery
• Installation and future maintenance
• The need to minimise disruption to production
The best solution is not always the most complicated. Sometimes a relatively straightforward modification can improve access, reduce downtime or make a task considerably easier for operators.
One-off items and ongoing production support
Bespoke stainless steel fabrication can cover everything from a single replacement bracket to complete fabricated assemblies.
For one-off items, an existing component can often be used as a pattern or starting point. For repeat requirements, we can retain templates and fabrication details to maintain consistency when customers need further items.
Having access to cutting, forming, welding, machining and finishing facilities in-house also allows different parts of a project to be coordinated through one workshop.
Stainless steel fabrication in North East England
Based in Blaydon on Tyne, Acorn Engineering and Fabrications has decades of experience supporting manufacturers with bespoke sheet metalwork and engineering solutions.
We work with businesses throughout North East England, manufacturing directly from customer drawings as well as helping to develop practical solutions for production and maintenance requirements.
From individual components and equipment modifications to complete stainless steel assemblies, we approach every project according to its intended use and working environment.
It has been a busy summer. A varied range of bespoke metal fabrication projects has passed through our North East workshop.
Recent work has ranged from components for food production environments to industrial pipework and decorative metalwork. This variety is a good example of what we do best. We produce practical, made-to-measure solutions rather than relying on standard, off-the-shelf products.
Fabrication for food production
We have continued to support customers within the food manufacturing industry. Recent projects have included fabricated items for both a large-scale food producer and a specialist tea manufacturer.
Work for food production environments often requires careful material selection, accurate fabrication and close attention to hygiene. Stainless steel is commonly used because it is durable, corrosion-resistant and easy to clean.
Every manufacturing site is different. Therefore, many of the items we produce are designed around existing machinery, production lines or restricted spaces. We can work from customer drawings, measurements, samples or an initial idea.
Industrial pipework and fabrication
Our industrial work has also kept the workshop busy. This has included the fabrication of bespoke pipework and associated components.
Industrial pipework must be manufactured accurately so that individual sections align correctly during assembly and installation. Depending on the project, the work can involve cutting, rolling, welding and fabricating several components into a complete assembly.
Producing this work in-house allows us to oversee each stage and respond to any practical issues that arise during fabrication.
Bespoke brass and copper features
Not every project is purely industrial. We have also been working with brass and copper to create bespoke decorative pieces.
Recent projects have included a made-to-measure brass sink, bespoke handles and copper feature lighting. These materials require a different approach from standard mild or stainless steel fabrication. Extra care is needed throughout cutting, forming, welding and finishing to protect the visible surfaces.
The final appearance is just as important as the construction. Small details can make a significant difference, especially when the finished metalwork will become a focal point within an interior.
No two weeks are the same
One of the most enjoyable parts of bespoke fabrication is the variety. A typical week can involve hygienic stainless-steel components, heavy industrial pipework and carefully finished decorative metalwork.
Whether we are working from a detailed drawing, an existing component or a customer’s initial idea, our aim remains the same: to produce a practical, well-made solution suited to its intended use.
If you have a bespoke metal fabrication project to discuss, please contact Acorn Engineering & Fabrications. We can help develop your requirements into a finished product.
Choosing the right material is an important part of any fabrication project. Strength, durability, appearance, working environment and cost all need to be considered before manufacturing begins.
At Acorn Engineering and Fabrications, we work with stainless steel, aluminium, mild steel and a range of non-ferrous metals, helping customers select a practical material for the finished application.
There is no one-size-fits-all material
A material that performs well in one environment may be unsuitable in another. The finished component may need to withstand moisture, chemicals, heat, regular cleaning, heavy loads or repeated use.
Appearance, weight, fabrication method and the required finish can also influence the decision. Understanding how and where the finished item will be used helps establish which material is best suited to the project.
Mild Steel: Strong and Versatile
Mild steel is widely used for structural frames, supports, brackets, machinery components, pipework and general industrial fabrications.
It offers good strength, is straightforward to cut, form, machine and weld, and is often a cost-effective choice. As untreated mild steel can corrode, the finished fabrication may require painting, powder coating, galvanising or another protective finish depending on its intended environment.
Stainless Steel: Durable and Hygienic
Stainless steel is commonly selected where corrosion resistance, hygiene or appearance is particularly important. It is frequently used for equipment, chutes, guards, trays, tanks and production-line components within food, beverage and pharmaceutical environments.
Different grades offer different properties. Grade 304 is suitable for many general applications, while grade 316 provides greater resistance in more demanding or corrosive conditions.
Stainless steel can also be supplied with a choice of surface finishes, from standard mill finishes to polished or decorative finishes.
Aluminium: Lightweight and Corrosion Resistant
Aluminium combines a low weight with good corrosion resistance, making it useful for panels, guards, enclosures, covers, frames and components that need to be handled or moved easily.
It can be cut, formed, machined and welded, although the chosen grade and thickness need to suit both the manufacturing process and the demands placed on the finished component.
Aluminium can be left in its natural finish or anodised, painted or powder coated where additional protection or a particular appearance is required.
Specialist and Non-Ferrous Metals
Some projects call for materials such as brass or copper because of their appearance, conductivity or other specialist properties.
These materials require suitable cutting, forming and joining methods to achieve a clean, practical result. Material availability and cost may also need to be considered during the early stages of the project.
Considering the Complete Fabrication Process
Material selection cannot be considered separately from the way a component will be manufactured. The required bends, welds, holes, tolerances and surface finish can all affect which material, grade and thickness should be used.
We can work from an existing CAD file, drawing, sketch or set of dimensions. By considering the complete manufacturing process from the outset, we can identify potential issues before fabrication begins.
From Material Selection to Finished Fabrication
With in-house CNC plasma cutting, machining, forming, welding and finishing capabilities, we can manage projects from the initial material and profile through to the completed component or fabrication.
Whether the requirement is for a one-off item, replacement component or a batch of repeat parts, we focus on producing a practical solution suited to its intended use.
CNC plasma cutting provides a fast and effective way to produce profiles and components from sheet and plate. Using computer-controlled equipment allows us to create consistent, repeatable parts for anything from a one-off requirement to larger batches.
How CNC Plasma Cutting Works
A plasma torch uses a high-temperature electric arc to cut through electrically conductive metal. The torch follows a programmed path created from a digital drawing, allowing detailed profiles, holes and shapes to be cut efficiently.
Our in-house Swift-Cut CNC plasma system can process mild steel, stainless steel and aluminium across a wide range of fabrication projects.
When plasma cutting is the right choice
CNC plasma cutting is particularly useful for brackets, base plates, gussets, flanges, panels and bespoke profiles. It can also produce shapes that would take considerably longer using conventional cutting, sawing and drilling methods.
Components can be produced individually or nested together on a sheet to make efficient use of the material and reduce unnecessary waste.
More than cutting a profile
A plasma-cut component may be the finished item, but it is often the starting point for a larger fabrication. Parts can be formed, machined, welded and assembled in-house to produce a complete component or fabricated structure.
Where holes or features require particularly close tolerances, additional drilling or CNC machining may be recommended after plasma cutting.
From drawing to finished component
We can work from an existing CAD file, drawing, sketch or set of dimensions. Before cutting begins, we consider the material, thickness, required tolerances and how the component will be used.
Combining CNC plasma cutting with our wider fabrication capabilities allows us to manage the process from the initial profile through to the completed item.
Customers do not always come to us with a finished drawing or clearly defined product. Often, they have a problem affecting an existing production line and need help developing a practical solution.
Understanding the problem
Products may be falling from a conveyor, bunching together or failing to move correctly between different stages of production. In other cases, unnecessary waste may be affecting efficiency.
The first step is to understand exactly what is happening, the space available and how the surrounding equipment operates. We may work from a sketch or take measurements on site. We may also discuss the problem directly with the people using the machinery every day.
Developing a practical solution
Once the issue has been identified, we can develop a solution that works with the existing process. For example, we may manufacture a chute, guide, guard, bracket or another bespoke component. This can help control product flow, reduce waste and make the equipment easier to operate and maintain.
Material selection is also important. We choose stainless steel, mild steel or aluminium based on the environment and application. We also consider hygiene, durability and ease of cleaning.
From fabrication to installation
Our in-house capabilities include CNC plasma cutting, machining, forming and welding. This allows us to manufacture both straightforward components and more complex fabricated assemblies.
Where required, we can also carry out installation and make final adjustments on site. This ensures the finished component works correctly within the existing production line.
Built around the application
Bespoke fabrication is not always about producing something from a completed drawing. Sometimes it begins with a practical problem and a conversation.
We combine workshop experience with an understanding of the application. This helps us turn an initial idea into a durable, workable fabrication solution.
