Profile Flattening During Bending: Predicting and Designing Around Deformation

Even with the correct alloy, radius, and tooling, bending inevitably changes the shape of an aluminum profile. Corners flatten, outer walls stretch, inner walls compress, and once-round sections start to become oval. These distortions affect stiffness, aesthetics, and fit-up with mating components. Understanding how deformation occurs—and how to design around it—is essential for achieving consistent, high-quality bends.