This calculator helps you estimate the minimum aluminum profile bending radius for common aluminum extrusion alloys such as 6061 and 6063, across their T4, T5, and T6 tempers. By entering the profile width and selecting the bending direction, you’ll get three reference radii based on varying elongation values.
These results are for reference only and reflect typical material behavior. In real-world bending, many profiles can be successfully formed using the maximum elongation value—producing excellent results without failure. However, actual performance depends on your material supplier’s specs, so always verify before production.
Use this tool during early design to avoid excessive trial-and-error and minimize scrap risk.
Aluminum Extrusion Minimum Bend Radius Calculator
Calculation Results of the Minimum Bending Radius of Aluminum Extrusion Profiles
| Temper | Allowed Elongation | Minimum Safe Inner Radius (mm) | ||
|---|---|---|---|---|
| Conservative (Min ε εmin=12%) |
Recommended (Avg ε εavg=15%) |
Risky (Max ε εmax=18%) |
||
| T4 | – | – | – | – |
| T5 | – | – | – | – |
| T6 | – | – | – | – |
Note on Elongation and Bending Radius Calculation:
This calculator provides estimated minimum bending radius values based on the elongation range of aluminum alloys 6061 and 6063 in their T4, T5, and T6 tempers. For example, 6063-T4 typically has an elongation between 12% and 18%, so we offer bending radius outputs for 12%, 15%, and 18% to reflect this range.
In actual production, bending at the higher end of the elongation range often produces better results and is widely practiced(For example, 18% of 6063-T4 ). However, please be aware that elongation values can vary depending on the extrusion manufacturer, specific profile design, and quality control. Always refer to the material test report (MTR) or consult your supplier for precise data before finalizing a bending process.
These values are for reference only. For critical applications, we strongly recommend validating the material’s properties through actual testing.
Material Properties:
| Alloy-Temper | Tensile Strength (UTS) | Yield Strength (YS) | Elongation (%) | Characteristics |
|---|
Primary Sources for Elongation Data
- “Aluminum Standards and Data” — Published by the Aluminum Association (USA) • This is the most widely cited aluminum alloy reference worldwide, detailing the mechanical property ranges of 6061 and 6063 in various heat-treated conditions. • It includes tensile strength (UTS), yield strength (YS), elongation, and more.
- ASTM B221 Standard — Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes • Defines the minimum mechanical properties for 6061 and 6063 in T4, T5, and T6 tempers.
- Metals Handbook — Published by ASM International • Contains measured and statistically compiled physical and mechanical properties of 6061 and 6063 aluminum alloys.
🔧 Need More Bending Geometry Tools?
For enhanced precision in bending design and machine setup, try our online bending geometry calculators:
- Arc Length Calculator – Calculate arc length from radius and angle.
- Angle Calculator – Find bending angle from arc length and radius.
- Radius Calculator – Work backward from arc length and angle.
👉 These tools simplify bending planning, reduce errors, and boost productivity.