Bent Aluminum Tubing

Chalco offers precision mandrel bent aluminum tubing in multiple angles—30° / 45° / 60° / 90° / 135° / 180°—crafted using advanced CNC forming to ensure consistent wall thickness and curvature. These aluminum bends are widely used in intake systems, exhaust systems, industrial equipment, performance vehicles, and HVAC structures.Welcome contact

Made from high-strength alloys such as 6061, 6063, 6005, and 3003, our products support OD sizes from 1.25" to 5.00", with options for round, square, and rectangular tubing. Chalco provides one-stop solutions, including material selection, precision bending, accessory configuration, surface treatment, and customized delivery—accelerating your project from design to production.

Product Categories of Bent Aluminum Tubing

30° Bent Aluminum Tubing

OD Range: 1.5" to 5.0"

Ideal for light-angle transitions, often used in the initial sections of intake or exhaust systems for directional routing and spatial optimization. A flexible solution for various engineering layouts.

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45° Bent Aluminum Tubing

OD Range: 0.75" to 5.0"

Provides medium-angle redirection, suitable for cooling systems, air intake ducts, exhaust transitions, and structural connections. Balances aerodynamic flow with spatial flexibility—popular in both custom modifications and industrial projects.

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60° Bent Aluminum Tubing

OD Range: Commonly from 1.0" to 4.0"

The 60° mandrel bend delivers compact turning performance for turbocharger piping, engine bay modifications, heater ducts, and motorsport exhaust layouts. More compact than 45°, yet smoother than 90°, it's ideal for optimized air routing in tight spaces.

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90° Bent Aluminum Tubing

OD Range: 0.75" to 5.0"

The most widely used standard bend, designed for areas requiring a clear directional shift, such as turbo intakes, coolant systems, oil flow corners, and structural elbows. Ensures optimal flow performance and mechanical stability—the top choice for efficient routing.

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135° Bent Aluminum Tubing

OD Range: 2.0" to 4.0"

Suited for sharp redirection without needing multiple connections, used in intake manifolds, targeted cooling paths, and performance exhaust systems. Reduces joints while maintaining smooth airflow.

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180° Bent Aluminum Tubing

OD Range: 1.5" to 5.0"

Creates a U-turn connection, essential in engine intake loops, cooling circuits, radiator bypass systems, and turbo airflow paths. Mandrel bending ensures uniform wall thickness and smooth curves, making it perfect for compact layouts and high-performance fluid dynamics.

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Chalco offers a wide range of mandrel bent aluminum tubing with customizable angles and dimensions. Whether you're building a standard intake system, an industrial frame, or a custom cooling route, we have the solution.

For custom specs, surface finishes, or CAD-based prototyping, contact us now for a tailored solution.Solution

Bent Aluminum Tubing Cross-Section Types

In aluminum tube bending, the cross-sectional shape determines both its structural purpose and bending complexity. Chalco offers precision bending services for various aluminum profiles—ranging from round tubes to square, rectangular, and custom extrusions—to meet diverse structural, decorative, and functional needs.

Round Aluminum Tubes

Bendable Size: Ø6mm - Ø219mm

The most common shape, ideal for fluid transport, intake/exhaust systems, heat exchangers, frames, and railings. Round tubes ensure even stress distribution, high concentricity, and excellent formability, making them suitable for mandrel bending, cold bending, and roll bending.

Square Aluminum Tubes

Bendable Size: 10x10mm - 180x180mm

Symmetrical on all sides, square tubes are widely used in structural frameworks, displays, racks, and architectural systems. Bending requires strict control of corner radii to prevent wrinkles or distortion.

Rectangular Aluminum Tubes

Bendable Size: 20x10mm - 150x100mm

Slightly harder to bend along the long edge, rectangular tubes are ideal for directional load-bearing structures such as table frames, support columns, and machine enclosures. Best suited for mandrel or roll bending.

Custom aluminum tube

Chalco supports custom bending for extruded, assembled, or non-standard aluminum shapes based on your CAD drawings. Common in guides, rails, heat sinks, and nonlinear frames.

*Pre-bend R-angle and section compatibility checks are required.

Chalco offers dedicated tooling and mandrels for each profile to ensure uniform curvature and high-strength results.Custom bent tube

Bent Aluminum Tubing Gallery

One-Stop Aluminum Tube Fittings Solution

Chalco offers a comprehensive range of aluminum elbows, tees, reducers, and flanges, providing systemized connection solutions for industries such as automotive, heat exchange, and rail transportation. We are committed to delivering high-precision, high-reliability fitting components and integrated support services to meet the diverse demands of complex piping systems.Quick Quote

Aluminum Tube Pipe Elbows

Aluminum Pipe Tee Fitting

Aluminium Reducer Pipe

Aluminum flange

Aluminum Alloys for Mandrel Bent Tubing

• 6063 bent aluminum pipe – Architectural Decorative

  Offers better ductility and bending formability than 6061, ideal for visual and lightweight structures.

  Recommended processes: Cold Bending, Roll Bending

  Surface finishes: Excellent anodizing (available in black, grey, color)

  Typical applications: Display frames, furniture, sunshade structures, LED supports

  *Anodized bent 6063 tube, 6063 aluminum elbow

• 3003 aluminum bend tubing – Corrosion-Resistant

  A manganese-based anti-rust alloy with good formability, best for medium/low-pressure systems and food-grade uses.

  Recommended processes: Mandrel Bending (thin-wall), Cold Bending

  Surface finishes: Suitable for polishing and coatings

  Typical applications: Cooling systems, food-grade tubing, outdoor HVAC, light-duty industrial bends

  *Corrosion-resistant bent aluminum tube, food grade bent pipe

• 6082 aluminum mandrel bend – High Strength Structural

  Combines high strength with good corrosion resistance. Suitable for structural parts under load.

  Recommended processes: Mandrel Bending (R ≥ 3D)

  Surface finishes: Anodizing or powder coating to enhance durability

  Typical applications: Crash bars, scaffold frames, sports equipment, load-bearing supports

  *high strength aluminum bend, 6082 T6 bent tube

• 7075 aluminum Bend tubing – Aerospace Grade

  Extremely high strength but limited ductility. Suitable only for large radius bends or low-stress structures.

  Recommended processes: Roll Bending, CNC-assisted Mandrel Bending (R ≥ 5D)

  Surface finishes: Not suitable for anodizing; use powder coating or electrophoresis

  Typical applications: Race subframes, RC aircraft parts, military-grade structures

  *7075 aluminum bend, aircraft-grade bent tube, 7075 U-bend

• 6005 aluminum Bend tubing – Medium Strength

  Offers good bendability and wall thickness stability; a cost-effective option for industrial applications.

  Recommended processes: Cold Bending, Mandrel Bending

  Surface finishes: Compatible with anodizing and powder coating

  Typical applications: Industrial frames, roof crossbars, advertising displays, window structures

  *6005 aluminum mandrel bend, 6005 bend pipe for framing

• 7001 aluminum bend tubing – Outdoor Equipment

  A heat-treatable alloy that balances strength and fatigue resistance, ideal for collapsible or lightweight structures.

  Recommended processes: Cold Bending, Roll Bending (R ≥ 4D)

  Surface finishes: Excellent anodizing; ideal for outdoor use

  Typical applications: Tent poles, telescopic tubes, outdoor sign mounts, adjustable connectors

  *Camping tent bent pole, lightweight telescopic bend

• 7005 aluminum bend tube – Weldable Outdoor Grade

  Similar to 7001 with enhanced weldability. Commonly used in hollow structural tubing with high fatigue resistance.

  Recommended processes: Mandrel Bending (preferably thick-walled)

  Surface finishes: Commonly anodized with rich color options

  Typical applications: Mountain bike frames, sliding rails, fitness equipment bends

  *Welded aluminum bike bend, sports equipment bend

Typical Applications of Bent Aluminum Tubing

Chalco's bent aluminum tubing is widely used across various industries, ranging from lightweight structural frames to complex fluid transmission systems. Key application sectors include:

Gas and Fluid Transmission Systems (Burners, Natural Gas Pipelines)

Thanks to its excellent thermal conductivity and corrosion resistance, aluminum bent tubing is commonly used as connection piping for gas or natural gas in equipment such as wall-hung boilers and ovens. 180° U-shaped mandrel bends are often used to achieve multi-angle spatial routing, reducing the need for joints and improving airtightness.

Aluminum Lighting Fixture Structures

Used for hanging lamp arms, mounting brackets, and track lighting systems, suitable for various installation methods. Due to its lightweight, corrosion resistance, and formability, it is widely adopted in commercial lighting, stage lighting, and decorative applications.

Medical Equipment and Handle Components

Such as push handles for mobile devices, auxiliary handrails on hospital beds, and wheelchair frames. Typically made from ¾″ or 1″ aluminum tubing via cold bending, these parts are precision-machined to follow ergonomic curves and finished with anodizing for antibacterial and easy-to-clean surfaces.

Shipbuilding and Marine Engineering Structures

Aluminum bent tubes are extensively used in yacht railings, boarding ladders, porthole frames, cockpit structures, sunshade frames, and offshore platform facilities. Alloys like 6061, 6063, and high-corrosion-resistant grades such as 5052 and 5086 are preferred, often treated with anodizing or marine-grade powder coatings for enhanced corrosion resistance.

Handrails and Structural Components for Transportation Equipment

Commonly found in public buses, subways, trams, and airport shuttles as interior safety handrails, vertical supports, seat frames, and auxiliary structures. 6061-T6 and 6063-T5 aluminum alloys are favored for their formability and corrosion resistance. Cold bending or roll bending ensures smooth, wrinkle-free finishes and comfortable grip.

Aluminum Cooling Coil Systems

Manufactured through continuous roll bending or mandrel bending, aluminum cooling coils are widely applied in air conditioning systems, heat exchangers, and thermal management modules for new energy batteries. A typical size is 3/8" OD x 32 Coil, with 3003 or 6063 aluminum alloys recommended for their thermal conductivity, strength, and bendability.

Industrial and Warehouse Cart Frames

Lightweight aluminum tube frames are bent via roll or cold bending to produce shelving, mobile tool carts, and display racks. Compared to traditional steel structures, these are lighter and corrosion-resistant—ideal for retail displays, warehouse logistics, and industrial equipment frames.

Foldable Aluminum Bicycle Frames

Aluminum bent tubing is used for lightweight bicycle frames and handlebars. 6061-T6 aluminum provides both strength and ease of assembly and anodizing. Manufacturing involves roll bending, combined with laser cutting and welding.

Sports Equipment and Fitness Structures

Widely used in products like adjustable pull-up bars and training equipment frames, aluminum bent tubes made from 6061 or 7005 alloys offer a high strength-to-weight ratio and excellent rust resistance. Mandrel or cold bending ensures smooth feel and solid structure.

Chalco offers versatile bent aluminum tubing solutions with fast customization based on industry standards or customer drawings, supporting batch prototyping and structural co-optimization.Quick Quote

Precision Bending Capabilities

In the manufacturing of bent aluminum tubing, Chalco possesses a complete industrial-grade processing system. We offer the following core bending processes, tailored to different diameters, wall thicknesses, and application requirements:

Core Bending Processes

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  Cold bending is a conventional bending process where the aluminum tube is deformed into the desired shape without heating. It is suitable for standard wall thicknesses and conventional tube diameters. Using dedicated clamp molds and rolling equipment, forming is quickly completed at room temperature.

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Common Applications:

Display racks, door and window frames, furniture tubing, decorative trim, etc.

Advantages:

• High processing efficiency and low cost, ideal for mass production of standard components.
• No heat treatment required after bending, maintaining surface integrity and preventing oxidation or discoloration.
• Suitable for light structural components, decorative pipes, and aluminum furniture with moderate precision and high production volumes.

Mandrel Bending

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  Mandrel bending is a high-precision forming process used for thin-walled aluminum tubes. A mandrel is inserted inside the tube during the bending process to prevent wrinkling, collapsing, and rebound. This process is ideal for complex angles and high-precision thin-walled tube structures.

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Applicable Scenarios:

Intercooler systems, racing exhausts, medical equipment supports, 180° U-shaped bends, etc.

Advantages:

• Supports tube walls to prevent wrinkling and deformation.
• CNC-controlled, ensuring consistency and precision for 30°–180° bends.
• Especially suited for tubes with wall thicknesses ≤ 0.065" and high-precision requirements.

Roll Bending

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  Roll bending is a process that uses three rollers to achieve large-radius continuous bending of aluminum tubes. It is ideal for creating long arc shapes with radii greater than or equal to 10 times the tube diameter (R ≥ 10D). Compared to cold bending or mandrel bending, roll bending is more suited for large-diameter tubes and smooth curves without sharp corners.

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Applicable Scenarios:

Building facades, long-arc frames, guide rails, sliding tracks, etc.

Advantages:

• Supports continuous large curvature bends with R ≥ 10D.
• Smooth, consistent bends without noticeable folds or wrinkles.
• Can bend aluminum tubes up to 6 meters in length, with stable accuracy.

Chalco's Bending Capabilities Highlights

• CNC Precision Assurance:Fully CNC-controlled tube bending system ensures angular error is controlled within ±0.5°, enabling highly consistent mass production.
• Wide Size Range:Supports outer diameters from 0.75″ to 5.0″, with a maximum bending length up to 6 meters (≈20 ft).
• Support for Various Production Volumes:Whether you need single-item prototyping, small batch trials, or large-scale production, we can quickly deliver your order.

Want to know which process is suitable for your project?

Click below to contact us and get personalized advice and sample solutions from Chalco's engineering team!Bend tubing advice

Post-Processing Finishing Options

To enhance the visual appeal, corrosion resistance, and functional adaptability of the finished products, Chalco provides a variety of surface treatment and secondary processing services, ensuring that your bent tube components are ready for installation.

Surface Treatment Options

• Anodized:Enhances corrosion resistance and offers multiple visual effects, such as silver, black, and red. Ideal for outdoor and decorative products.
• Polished:Suitable for applications requiring high shine and cleanliness, such as medical devices and racing exhaust systems.
• Powder Coating / Spray Coating:Offers corrosion resistance and UV protection, making it perfect for industrial and transportation applications.

Secondary Processing Capabilities

• Thread-After-Bend:Enables precise threading on the aluminum tube after bending, making it easy to connect and fix.
• Tube End Forming:Compatible with common fittings and seals, supports processes such as flaring, necking, and expanding tube ends.
• Flared / Beaded Ends:Used for hose connections, air-tight closures, or pressure sealing applications.
• Punching / Slotting:Applied for bracket positioning, guide rail guidance, or structural assembly.
• Cutting Drilling:Custom length cutting and hole drilling as per drawings, enhancing assembly efficiency.
• Welding:TIG, MIG, and other welding methods, suitable for reinforcing structural components or integrated assembly.

If you require custom post-processing services, click below to contact us and receive sample and technical selection advice.Contact us

Aluminum Mandrel Bending Technical Parameter Summary Table

Frequently Asked Questions

Why should I choose mandrel bending over standard press bending for tight spaces in my project?

Standard press bending often causes internal wrinkles, external thinning, or even collapse in small spaces, which can affect flow efficiency and structural reliability. Mandrel bending provides internal support, ensuring the tube maintains its round cross-section even at very tight radii like 1D or 1.5D, making it ideal for complex layouts like intercoolers, turbo intake, and exhaust U-loops.

I'm concerned about inconsistent angles in different batches of mandrel-bent tubes. How does Chalco ensure consistency?

We use a CNC-controlled mandrel bending system along with simulated bending compensation. Each bend angle is controlled by CNC programs, with angle tolerances within ±0.5°. We also standardize the centerline radius (CLR) and leg length to ensure strong interchangeability for batch products and minimize rework during assembly.

What does "CLR" mean for bent tubes, and how do I choose it?

CLR stands for Center Line Radius, referring to the radius of the tube's centerline during bending. Common sizes include 1D, 1.5D, and 2D (where "D” is the tube's outer diameter). Typically:

• 1.5D is suitable for standard structures.
• 1D is more compact and suitable for limited space or high flow path requirements.
• The smaller the radius, the higher the process requirements.

The bent tube I need isn't available on your website. Can I customize it?

Absolutely. Chalco supports custom designs based on your drawings, including special outer diameters, wall thicknesses, bend angles, lengths, and connection ends. We offer small batch orders, free samples, and technical drawing confirmation services.Customized

Does 6061 mandrel bending crack at the edges? What if I need welding?

6061 in T6 condition is indeed harder, and conventional cold bending may cause cracks. Chalco uses 6061-T4 core material for bending, which is then age-hardened to T6, retaining high strength while avoiding edge cracking. Additionally, this material offers excellent weldability, making it ideal for full-weld systems.

Will different wall thickness and outer diameter combinations affect airflow? How should I choose?

Wall thickness (ga) and outer diameter (OD) combinations influence bending strength, airflow, and heat dissipation performance. For example:

• 16ga thickness is suitable for general modifications and standard fluid systems.
• 2.0mm thickness is better for turbo/supercharged systems, racing intake/intercooler systems, offering stronger explosion and heat resistance. If you have specific fluid parameters or thermal expansion limitations, please contact us for fluid path and structural simulation advice.

I need tubes for marine or outdoor environments. Can you ensure corrosion resistance?

No problem. We offer industrial-grade anodizing (Anodized), polishing (Polished), and powder coating (Powder Coated) surface treatments. We particularly recommend black anodizing, which effectively resists salt spray corrosion, making it ideal for coastal/offshore equipment, dusty environments, and outdoor transportation systems.

Can your U-bends (180°) have long legs? I need both ends to be of equal length for fixation.

Of course. We can customize U-bends with the specified leg lengths based on customer drawings, ensuring both ends have consistent tangents, making it easy for flange connections, bracket installations, or aluminum welding for intercooler systems.