Blechexpo 2025 in Stuttgart is focusing on the entire tube machining process chain – from the material feed and programming process to final machining and bending. In this setting, WAFIOS will be presenting highly specialized CNC tube bending machines that integrate seamlessly into this process chain and take a fresh approach to each individual step. With the unique Apple Vision Pro system, the company will showcase a right- and left-bending machine that can accommodate up to 100 mm – the TopBend 100. Although the demonstration will be virtual, visitors will still be able to experience the machine for themselves.
Precision meets performance: the RBV 25 R-KSB
The RBV 25 R-KSB CNC tube bending machine was developed for producing headrest frames. These are both important safety components and visual elements in car design. For production purposes, the tubes in these components have to be orientated with precision before machining – and they also involve short, straight sections, 180° bends, and fast cycle times. This makes it difficult to achieve outstanding quality while still producing parts in large quantities.
The RBV 25 R-KSB CNC tube bending machine is a small, compact and fast right- and left-bending machine. With its multi-level bending tool structure, the machine is able to deal with not only short clamping lengths, but also a variety of bending radii within a component. The tools are also developed in-house by WAFIOS.
Material feed with automatic tube orientation
Tubes are orientated directly on the magazine for further machining. A tube rotating device performs the orientation task. There are various options available for identifying features such as weld seams and notching: An eddy current sensor identifies invisible weld seams, while an optical sensor or camera can be used to detect visible ones. The camera also recognizes other visual features such as logos, lettering and QR codes.
The loading unit takes the tube from the magazine and positions it in the CNC tube bending machine. Pre-positioning is performed at almost the same time as the previous tube is unloaded, ensuring quick changes. The process of orientation on the magazine is ideal for series production.
In other application areas such as the furniture industry, the patented iQ function iQtubeorientation is available as an optional alternative. The iQ function enables tubes that have punched-in holes or are marked to be orientated in the collet fully automatically. This function is integrated into the machine. The feed equipment can be used to place the tube in the collet from any position. The tube is then oriented and positioned for the bending process by means of a camera.
Intelligent programming for immediately true-to-gauge parts
Regardless of how well a machine is set up, the production process is always faced with the challenge of the actual geometry differing from the required geometry. The reason for this lies in the bending radii springing back during rotary-draw bending. As a result, the bent part fails to achieve the required geometry in full. Now, this discrepancy can be resolved using the WAFIOS Programming System WPS 3.2 EasyWay. The new software feature automatically compensates for radius deviations and calculates the radius increases that occur during bending on the basis of the material data. This allows the component geometry to be adapted as required. The operator can then achieve a true-to-gauge good part more quickly as a result. Less setup time and material are also needed in this case.
Isometric programming: added efficiency thanks to a spatial display
Unlike conventional programming methods such as LRA (length, rotation, angle) or XYZ coordinates, the programming in this case is based on a spatial display of the tube geometry in an isometric view. This graphics-based programming method makes it easier to visualize the component geometry. In turn, this reduces input errors as the display resembles the actual component geometry more closely. Additionally, this makes it easier to program complex geometries with multiple bends and changing levels. Isometric programming is available in addition to and as a complement to conventional methods. It is particularly useful for manufacturing position-oriented parts of the kind required in mechanical and plant engineering.
Dive into a digital world
At Blechexpo 2025, WAFIOS will be using Apple Vision Pro to present a digital booth concept. Apple Vision Pro provides a high-resolution image that will make visitors feel as though they can almost reach out and touch the machine. VR headsets will be available for visitors to experience a range of different WAFIOS machines in a digital space. These include the TopBend 100, the RU 12 pipe forming machine and WAFIOS Tube Automation for end forming. The WAFIOS team warmly invites all visitors to come and dive into this virtual reality experience!
The TopBend 100 is a CNC tube bending machine for tube diameters of up to 100 x 4 mm and joins the existing TopBend 35 model. It is based on familiar RBV tube bending technology. The weight and speed concept has been optimized for high performance. The TopBend 100 provides a high-strength machine concept with a rated bending torque of 20,000 Nm in accordance with VDI 3432 and fully fledged right and left bending, each with a 250 mm tool installation height. With this machine, WAFIOS is presenting a right- and left-tube bending machine that can accommodate up to 100 mm, opening up new possibilities for production in the relevant pipe dimension ranges.
Visit WAFIOS at Blechexpo 2025 in Stuttgart from October 21 to 24.
Hall 3, booth 3402
