Fabrication
Technical Fabrication & Aluminium Bending
Façade Creations operates with one of the most significant capacities for aluminium and non-ferrous section bending in the UK. Our facility is equipped to handle sections up to 400mm on plan and up to 700mm in sectional size on elevation. We specialize in curving thermally broken and pre-painted aluminium window sections up to 7000mm in length, with the capability to handle total lengths reaching 13600mm.
By combining advanced technology with a highly skilled technical team, we handle complex extrusion bending requirements that set the standard in the architectural market. Our engineers provide expert guidance during the inquiry stage, advising on the bending limitations of specific sections and offering innovative alternative solutions to achieve your design goals.
Versatile Material Bending
While our primary focus is aluminium, our machinery and specialized tooling allow us to roll a variety of materials, including:
- Stainless Steel
- Brass
- Steel Sections
We produce a wide range of radii, including intricate elliptical curves for high-end architectural applications. Our in-house tooling facility enables us to modify and produce bespoke bending tools quickly and economically, ensuring project timelines are met with precision.
Advanced Bending Methods
To maintain the structural integrity and surface quality of every section, we utilize various specialized methods:
Aluminium Roll Bending
An extremely cost-efficient method for forming aluminium sections. By placing the section between three adjusted bending rolls, we can create complex shapes and curves with great versatility.
Aluminium Mandrel Bending
This method is best suited for thin-walled profiles that might not withstand other types of pressure. Each section is fed through a precision machine to ensure fast, highly accurate results without compromising the profile.
Aluminium Stretch Bending
Stretch bending applies force to both ends of the material over a central bending mould. The constant tension reduces deformation of the cross-section, making it the ideal choice for projects requiring superior surface quality, such as those in the aviation or architectural industries.
The Encapsulation Method
For pre-painted or delicate sections, our encapsulation method allows for curving without the need for expensive tooling. This process ensures the paintwork remains intact and undamaged throughout the bending cycle.
Industry Applications
Our fabrication expertise supports a diverse range of sectors and high-scale industrial projects. We have provided services for major construction landmarks, including international stadiums and advanced production centres.
Industries we serve include:
- Architectural: Facades, shopfronts, and specialized window systems.
- Commercial: Office furniture, partition screens, and internal design fit-outs.
- Engineering: Aerospace, automotive, marine, and medical equipment.
- Infrastructure: Railway components and large-scale metalwork.
Frequently Asked Questions (FAQs)
- What is the maximum length you can bend?
We can curve sections up to 7000mm for standard window profiles and have the capacity to handle total lengths of up to 13,600mm. - Can you bend pre-painted aluminium without damaging it?
Using our specialized encapsulation method, we can curve painted sections while ensuring the finish remains in perfect condition. - What are aluminium extrusions?
Extrusions are created by pushing heated aluminium through a shaped die. This allows for complex cross-sectional designs used throughout the manufacturing industry. - Do you provide bending for materials other than aluminium?
While we are specialists in aluminium, we also have the tooling to bend stainless steel, brass, and other steel sections. - What is the smallest diameter you can achieve?
This depends on the specific section and material grade. Our engineers can advise on the exact limitations once they review your profile. - Are your manufacturing processes certified?
Yes, we operate with an ISO 9001 Quality Management Certification, ensuring precision and consistency across all fabrication tasks. - What is a thermally broken profile?
It is an aluminium section with a reinforced polyamide bar between the inner and outer profiles, which significantly reduces heat transfer and improves energy efficiency. - Do you provide in-house powder coating?
Yes, we offer architectural powder coating to any standard RAL colour, providing a finish that is often double the industry standard for thickness. - How does stretch bending differ from roll bending?
Stretch bending uses tension on the ends of the material to prevent the profile from collapsing or deforming, which is essential for maintaining high-quality surface finishes. - Can you assist with the initial design of a curved project?
Our expert design and engineering team can work with your blueprints to determine the most effective bending method for your specific project.
