Precision from prototype to full production
Bauer delivers precision tube bending services that always meet specs and deadlines, keeping even the most complex projects on schedule.
Bauer guides you from initial prototyping through full-scale production with in-house Design-For-Manufacturability (DFM) review, robotic welding and one of the region’s largest bend die libraries. All while simplifying supply chains, improving quality and accelerating timelines.
Make fabrication easy and efficient at every step
Do you need speed, consistency and cost-efficiency at every step?
Bauer provides precision bending, robotic welding, and proactive engineering — all in one domestic shop. You can expect rapid service to keep your projects moving and get you deliveries faster while maintaining exemplary quality standards.
With expert DFM preparation, we hit your specs the first time. Our electric bending cells reliably hold tight tolerances of approximately 1/32 (.03125”) of an inch. And you may be able to get it without the added cost of tooling, even on complex parts.
Unmatched complexity, unique capabilities
Skip the runaround and work with the best for all your tube bending. Bauer is the only partner you need for the most complex assemblies.
You can make your most challenging projects seem simple with an unmatched array of precision services under one roof.
Capabilities include:
- Mandrel and tight-radius bends
- Push bending and roll bending
- Single, double or triple-stack heads for multi-radius bends
- Complex part shapes and compound bending
- Coil and corkscrew configurations
Built for product launches
Start projects faster and more affordably with Bauer’s in-house fixturing, tooling, and bend die inventory.
Bauer’s die library — one of the largest in the field — houses thousands of pre-built tools. That drastically reduces lead times and custom tooling costs, helping you get to market faster and protect early production quality.
You can count on:
- In-house fixture design for faster ramp-up
- Extensive bend die library eliminates high tooling costs for many programs
- Avoid weeks of tooling delays typical with other vendors
- Robotic welding ensures consistency and throughput
Engineering collaboration included
We don’t just build from files and hope for the best. We won’t fabricate anything until everything is DFM ready. Bauer’s engineers proactively review your files to catch issues early and recommend improvements that save time and cost.
We help you with:
- Design-for-manufacturability (DFM) feedback
- Tolerance and material guidance
- Collaborative quoting with redline support
Technical capabilities
Bauer is uniquely qualified in mandrel bending, push bending, complex and tight-radius bends, coil and corkscrew configurations, and roll bending utilizing single, double or triple-stack heads for multi-radius bends.
| Capability | Spec |
|---|---|
| Outside diameter (OD) | .125 in. to 5.00 in. (round); square & rectangular supported |
| Wall thickness | 3/8" to 5", up to 7 gauge, 0.028" wall to 0.250" wall |
| Bend method | NC & CNC mandrel bending; rotary draw; press bending; push-bending; compression (if applicable) |
| Bend angle accuracy | ±.1° typical |
| Bend location tolerance | 37°/45° flares, beading, expanding/reducing, swaging, piercing, threading |
| Cutting | CNC laser |
| Welding | MIG, TIG, robotic; |
| Materials | Mild steel, chromoly, stainless, aluminum, copper |
| Volumes | Prototype, preproduction, and production |
| File formats | STEP, IGES, Parasolid, SolidWorks [.sldprt, .sldasm, .slddrw]; DXF for flats; PDF for prints |
Why product teams count on Bauer
These engineers and buyers faced tight deadlines, tough specs and last-minute changes. Hear how Bauer helped them deliver.
"They're saving at least $15 on a piece cost and hundreds of thousands on initial tooling expenditure."
– Brad Merola, Engineering Program Manager, AEV
“Bauer has overall fantastic service, and I like working with the team. You don’t want to work with someone you don’t like. So, it’s extremely important to develop a strong relationship.”
– Stephen Duley, Commodity Manager, Generac Power Systems
“Bauer does a nice job with being upfront. If there's any exceptions or they're suggesting an alternative material or they're requesting additional tolerance on something, they're making sure they do their front-end work, which is good to see.”
– Alex Nelson, Procurement Manager, SICO
Pricing factors
Piece count
We support prototyping as well and help find cost efficiencies all the way to full production. You also can access reduced pricing for larger runs of 500 or more assemblies.
Part complexity
The number of bends, welds and components in your process affects time and cost.
Material type
Mild steel is often the most cost-effective option. You can improve performance but increase costs by selecting stainless steel, aluminum or adding coatings like zinc or chrome.
Tooling needs
You can reduce or remove tooling costs with our in-house fixture library. Custom tooling or unique fixturing for specialty parts may impact your quote.
The Bauer four-step process
1. Submit your part design
Send us your designs. We will contact you within one business day and provide an initial quote in less than a week.
2. Get expert Design-For-Manufacturability feedback
Work with our expert engineers to optimize for quality and manufacturability.
3. Fabricate your parts
Our expert in-house technicians cut, bend, weld and form your tubes, delivering them on schedule.
4. Launch your product
You deliver products to your customers on time, on budget and at a superior quality.
Ready to simplify your supply chain?
Stop wasting time chasing vendors, reworking bad parts or re-explaining designs. Get fast answers, reliable schedules, and assemblies that install easily from the first to last.