How Valley Metal Works Used In-House Tooling to Improve Steel Pipe Forming
A machine builder producing components for roller coaster vehicles needed a reliable way to flatten steel pipe while maintaining the dimensions required for the finished part. Standard press brake tooling was not suitable for the geometry, and inconsistent forming could affect fit, repeatability, and downstream assembly.
Valley Metal Works designed and built custom press brake tooling specifically for the application. The tooling allowed the steel pipe to be formed to the required shape while maintaining dimensional control throughout production.
The project also required AWS D1.1 welding certification, adding defined welding and fabrication requirements to an already specialized forming application.
Project Challenge: Forming Steel Pipe Without Losing Dimensional Control
Flattening steel pipe creates different forming challenges than bending flat sheet or plate. As the pipe is compressed, the material can deform unpredictably if the tooling does not properly control the finished geometry.
For this roller coaster component, the customer needed a repeatable process that could:
- Flatten the steel pipe to the required geometry
- Maintain critical finished-part dimensions
- Produce consistent components across the production run
- Support subsequent welding and assembly
- Meet the project’s AWS D1.1 welding requirements
Custom Press Brake Tooling Designed In-House
Rather than adapting standard tooling to a non-standard forming operation, Valley Metal Works designed tooling around the component itself.
The team reviewed the required finished geometry and developed a press brake tooling configuration capable of controlling the pipe as it was flattened. Designing the tooling specifically for the part established a more repeatable forming process and reduced reliance on manual adjustment during production.
This approach was important because the finished dimensions were determined by more than press brake force alone. Tool geometry, material movement, and the way the pipe was supported during forming all affected the final shape.
By addressing those variables through dedicated tooling, the forming operation could be built around the customer’s finished-part requirements.
Fabrication and AWS D1.1 Welding Requirements
After forming, the components also had to meet the welding requirements specified for the project. AWS D1.1 applies to structural welding of steel and establishes requirements related to qualified welding procedures, personnel, fabrication, and inspection.
For this project, Valley Metal Works combined the custom forming operation with welding capabilities that met the specified D1.1 requirements.
Why Custom Tooling Mattered
The tooling solved a manufacturing problem that could not be addressed effectively with an off-the-shelf press brake setup.
Instead of accepting variation and correcting components later, Valley Metal Works developed the forming process around the required final geometry. This gave the machine builder a more controlled method for producing the roller coaster components and supported repeatability from part to part.
For OEM and machine-building projects, this type of tooling development can be especially important when a component involves:
- Unusual tube or pipe geometry
- Repeat forming operations
- Tight dimensional requirements
- Specialized assemblies
- Production quantities that justify dedicated tooling
- Parts that must fit consistently into welded assemblies
Project Results
The custom tooling successfully produced the required flattened steel pipe components during the first production run.
Following completion of the project, the machine builder earned preferred-supplier status for the components. The result demonstrated that the forming method could support the customer’s ongoing production requirements rather than functioning as a one-time fabrication workaround.
Results at a Glance
- Custom press brake tooling designed and manufactured in-house
- Repeatable process developed for flattening steel pipe
- Required component dimensions maintained during forming
- AWS D1.1 welding requirement supported
- Successful initial production run
- Machine builder secured preferred-supplier status for the components
Metal Fabrication Capabilities Used
Industry: Amusement ride manufacturing / machine building
Application: Roller coaster vehicle components
Material: Steel pipe
Primary process: Press brake forming
Tooling: Custom tooling designed in-house
Welding requirement: AWS D1.1
Frequently Asked Questions
Can custom press brake tooling be used to form steel pipe?
Yes. When standard press brake tooling cannot maintain the required geometry, tooling can be designed around the pipe diameter, wall thickness, material behavior, and desired finished shape. In this project, custom tooling was developed specifically to flatten steel pipe while maintaining the required component dimensions.
Why use custom tooling instead of standard press brake tooling?
Custom tooling provides greater control when a part has geometry that standard punches and dies are not designed to produce. It can also improve repeatability when the same specialized forming operation must be performed across multiple parts.
Can forming and welding be handled by the same metal fabrication supplier?
For projects that require both operations, using one fabrication partner can simplify coordination between forming, fit-up, welding, and inspection. In this project, the components required both specialized forming and AWS D1.1 welding capability.
What information is needed to evaluate a custom pipe-forming project?
At minimum, a fabricator typically needs the material specification, pipe diameter, wall thickness, finished geometry, dimensional tolerances, quantity, drawing requirements, welding requirements, and expected production schedule. Those details determine whether existing tooling can be used or dedicated tooling should be developed.
