Bent, Rolled, and Punched: Precision Machinery Accelerates Throughput
The advanced automation and AI functionality at work in modern, energy saving metal forming machinery supports manufacturers in achieving not only operational efficiencies but also reduces labor costs and minimizes material waste streams.
Roll Bending Lineup Scales Your Production with Confidence
Nargesa roll benders have earned their place in fabrication shops by delivering the control, consistency, and scalability that modern forming demands. The lineup spans from entry-level machines to fully CNC-controlled systems, allowing shops to handle everything from one-off work to high-volume production with confidence. Quantum Machinery (Mooresville, NC) is the exclusive United States importer of Nargesa roll benders.
The range includes both two-drive roll and three-drive roll configurations. Two-drive roll machines provide efficient, dependable performance for a wide range of standard bending applications. Three-drive roll systems bring added traction and control, which becomes important when working with heavier materials, tighter radii, or more demanding profiles. This gives fabricators the ability to choose a machine that fits the work in front of them without compromise.
As production requirements increase, Nargesa machines scale with them. Advanced models introduce digital controls and full CNC capability, allowing operators to store programs, repeat exact bends, and maintain consistency across every run. This improves workflow, reduces setup time, and keeps results consistent from part to part.
Across the entire range, build quality remains consistent. Rigid steel construction ensures stability under load, helping maintain alignment and accuracy over time.
AI Plate Rolling Measuring System
Davi, Inc.’s (Addison, TX) AI-Vision laser radius in-process plate rolling measuring system is the next generation of the company’s i-Vision. The system represents the augmentation of AI into the plate rolling process.
AI-Vision makes the plate rolling process significantly easier and provides better results not only for experienced operators, but also for those that are less experienced. Because the system eliminates the need for measuring with manual templates, it improves plate rolling accuracy and speed, while helping to reduce scrap.
The AI-Vision applies to Davi’s line of all-electric plate rolling machines. The MCE e-POWER machines feature extremely precise technology that achieves a positioning accuracy of 0.05” (1.27 mm), compared to the typical 0.1” (2.54 mm) precision found on conventional plate rolling machines.
To capitalize on this precision, AI-Vision uses a “laser blade” as opposed to a single laser beam point for in-process measuring. Employing a laser beam in the non-visible spectrum, the blade scans a wider rounded area, recording thousands of points along the curved surface of a radius at one time.
The system ignores atypical readings and, instead, takes an average of all data points captured by the laser blade. This provides an accurate picture of the plate and eliminates the risk that material hard spots and irregularities, surface mill scale and shop environmental conditions such as incidental light reflections could negatively affect the measurements.
With the combination of AI and a specific algorithm, AI-Vision transmits the readings and measurements directly to the plate rolling machine’s CNC where process adjustment data is calculated to automatically adjust the machine’s side rolls in real time. This streamlines the rolling process and ensures the most accurate results in the shortest amount of time possible.
Consistent, Repeatable Bending Without the Energy Demands
KAAST Machine Tools, Inc. (Aldan, PA) has introduced its HPB-E Servo-Electric Press Brake, which is designed to help fabricators reduce energy use, achieve high precision, and increase efficiency in modern production environments.
The HPB-E addresses the industry’s shift toward energy-efficient, low-maintenance equipment. By eliminating hydraulics, the machine reduces energy use by up to 50% compared to conventional press brakes. It also lowers maintenance and operating costs. The HPB-E is available in configurations up to 100 tons and bending lengths up to 3,200 mm (126”), supporting a wide range of fabrication applications.
Equipped with a servo-electric drive system, the HPB-E delivers bending accuracy up to 0.01 mm (0.0004”) with consistent repeatability. Its Delem DA-58T touchscreen control system features 2D graphical programming and automatic bend sequencing, simplifying complex setups and reducing production downtime. High-speed operation allows increased throughput without sacrificing part quality.
“Fabricators are under increasing pressure to improve accuracy while lowering operating costs,” said Chris Golas, sales manager at KAAST. “The HPB-E delivers consistent, repeatable bending without the energy demands and maintenance associated with hydraulic systems.”
The HPB-E is suited for applications including sheet metal fabrication, appliance manufacturing, automotive components, and other high-precision production environments.
Maximize Multi-shift Productivity with Automatic Channel Processing Systems
Trilogy Machinery, Inc. (Belcamp, MD) has installed more than a dozen Sunrise Automatic Channel Processing Systems (Model ACPS) in less than two years. This fully automated channel line punches and shears up to 50’ of C3-C6 channel. Standard with a 60-ton punch, featuring dual independent 1.5” capacity punches and a 100-ton double-cut shear, the ACPS streamlines production with punching, shearing and nesting capabilities.
The ACPS features a fully integrated punching and shearing cell, including safety-interlocked doors and light curtains, 27” touchscreen controller, Wi-Fi and more. The automated in-feed runs on dual linear rails guided by a high-speed rack-and-pinion servo motor, allowing up to 480”/min travel speed and boasts an impressive 0.004”/foot accuracy.
The ACPS excels in multi-shift and demanding fabrication environments, helping shops reduce manual handling and accelerate throughput. Its automated design makes it a strong fit for operations seeking greater consistency and reduced downtime in channel processing applications. Optional tooling, including multi-head punches, further adds to its processing capabilities.
Trilogy Machinery is the exclusive United States distributor for Sunrise Ironworkers and Processing Lines. Trilogy stocks more than 50 models of Sunrise machines from 40-to-220 tons. A multi-year warranty, dedicated in-house technicians, lifetime tech support, and a full contingent of spare parts come standard.
Special Tooling Maximizes Customer Productivity
At Scotchman Industries, Inc. (Philip, S.D.), special and custom tooling is engineered with one goal in mind: helping fabricators work faster, cleaner and more efficiently. When customers require specialized tooling for their ironworkers, Scotchman designs and manufactures solutions that transform complex production challenges into streamlined, repeatable processes.
A recent custom punch tool highlights this commitment to performance and precision. Designed specifically for Scotchman Ironworkers, the tool punches four holes simultaneously in mild steel — dramatically increasing throughput without sacrificing accuracy. In a featured demonstration, the system produces 9/16”-×-1-1/8” oval holes using a shear top punch, delivering clean, consistent results while operating at maximum rated tonnage.
Flexibility was a key focus in the tool’s design. The punches can be rotated 90°, and the system accommodates virtually any hole shape using standard #40 punches and #82 dies. For improved material handling, the stripper assembly can be configured for left-to-right feeding, allowing the tool to adapt to various shop layouts and workflow requirements.
To enhance repeatability and reduce setup time, a custom stop was integrated into the stripper plate to ensure consistent material positioning during production runs. Like all Scotchman special tooling, this feature can be tailored to the specific application, improving both efficiency and accuracy.
Key design features:
- Fixed 4” center-to-center hole layout.
- Individually adjustable die holders for precise alignment.
- Engineered to handle full ironworker tonnage capacity.
- Heavy-duty construction for long-term durability.
- Application-specific features customized to customer requirements.
This project demonstrates how Scotchman’s special tooling solutions are developed around real-world fabrication demands. From multi-hole punching applications to fully customized layouts, the Scotchman team collaborates closely with customers to create tooling that integrates seamlessly with the complete line of Scotchman Ironworkers — helping manufacturers increase throughput and maintain consistent quality.
Configuration Tool for Tube Bending
OSH Cut, Inc. (Spanish Fork, UT), an online metal manufacturer, offers a first-of-its-kind configuration tool that allows users to design bent tube parts from scratch, if they don’t already have a 3D CAD model. Those part files can then be queued up for production immediately or downloaded as .STEP files for later use.
OSH Cut’s tube bending services will initially be limited to steel (A513, 4130, and DOM 1020), stainless steel (304), and aluminum with varying diameters up to 1.5” and wall thicknesses up to 0.120”, depending on the material. Additional equipment/tooling to bend up to 3”-diameter tubing will be in place this year. If customers just need straight tube cutting service, the company can cut parts up to 10” in outer diameter.
CNC tube bending was one of OSH Cut’s top requested services in 2025, according to customer survey data. Some of the more popular applications for custom cut and bent tubing include automotive framework, furniture making, robotics, railings, conduit, etc.
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