Brake Press Material Selection Guide
Not all metals bend the same. Ductility, springback, grain direction, and surface quality vary dramatically by alloy.
Mild Steel (A36, 1008/1010)
The easiest material to form. Low springback (1–3°), excellent ductility, bends to 1x material thickness radius without cracking. The standard material for structural brackets, enclosures, and general fabrication. Minimum bend radius equals material thickness in most cases. Consistent, predictable, and forgiving — the ideal brake press material.
Stainless Steel (304, 316)
Higher springback than mild steel (3–5°). Work hardens during forming — successive bends get harder. Requires 50% more tonnage than mild steel at equivalent thickness. Minimum bend radius: 1.5x material thickness. Surface scratching is a concern — use protective film or polished tooling on cosmetic parts. 304 is easier to form than 316.
Aluminum (5052, 6061, 3003)
Formability varies wildly by alloy and temper. 5052-H32: excellent formability, moderate strength, minimum IR = 1x thickness. 6061-T6: poor formability, high springback (4–6°), minimum IR = 3x thickness, prone to cracking. 3003-H14: most formable aluminum, minimum IR = 0.5x thickness. If your design requires tight bends in aluminum, specify the alloy carefully — 6061-T6 is the most common mistake.
Galvanized Steel
Forms similarly to mild steel but the zinc coating can crack or flake on tight bends. Hot-dip galvanized cracks more readily than galvanneal. Minimum bend radius: 1.5x material thickness to protect the coating. The zinc layer acts as a lubricant, reducing friction between the tooling and work — this can cause parts to shift during forming if not properly clamped.
High-Strength Steel (HSLA, AR400, Hardox)
Yield strengths from 50 ksi to 160+ ksi. Tonnage requirements are 2–5x mild steel. Springback is 5–10°+, requiring significant CNC over-travel compensation. Minimum bend radius: 3x–5x material thickness depending on grade. Some ultra-high-strength steels (AR500, Hardox 600) should not be brake-formed — they will crack. Check the manufacturer's bend recommendations before designing.
Copper & Brass
Excellent formability. Dead soft copper bends to 0x radius (fold flat) without cracking. Half-hard copper: 1x thickness. Brass (C260): 1x thickness minimum. Springback is low (1–2°). The main challenge is surface marking — copper and brass show every tooling impression. Use urethane pads or protective film for cosmetic work.
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