Rebend

Rebend, or re-bending, is a term used in sheet metal fabrication to describe the process of bending a previously formed workpiece again to reach a final geometry or to correct an earlier bend. It is common when initial bending does not meet tolerances, when multiple bends are required in a single feature, or when springback after the first bend alters the intended angle.

Process: Rebend is performed on a press brake or similar bending tool. The part is repositioned or rotated to align the bend axis with the tool, and appropriate die radii and bend angles are chosen to minimize defects. Techniques to reduce springback include using tighter bend radii, correcting for material springback in the bend plan, applying backgauging, using fixtures, and sometimes performing a progressive or staged bending sequence. In some cases, heat treatment or annealing may be used to reduce springback or improve ductility, though this adds process steps and cost.

Applications: Rebend is used in automotive brackets, enclosures, appliance components, and other sheet metal assemblies where complex geometries require more than one bending operation or where a first bend must be corrected. It is also relevant for tubing and wire bending in some contexts, though practices differ from flat sheet metal.

Quality and considerations: Material properties such as yield strength, ductility, and work-hardening behavior affect a rebend. Designers must account for bend allowances, bend radii, and potential cracking at the bend line. Precision hinges on measurement and inspection of bend angles, radii, and overall geometry.