About Bend Genius & FAQ

What is Bend Genius?

Bend Genius is a web-based tool for use with air bending sheet metal on a press brake using a vee die. BG is a calculator that runs several industry accepted rule-of-thumb logical checks, along with a series of ever-increasing custom developed formulas to provide guidance when working with sheet metal bending.

Bend Genius is easy to learn for those with only basic bending knowledge, and yet is valuable for all skill levels – even your manufacturing engineers will find it surprisingly helpful to have these calculations completed automatically. Bend Genius will help your team bend smarter by:

  • Identifying many part geometry errors before they reach the shop floor
    • Minimum Leg Length
    • Hole & slot deformation distance
    • Inside bend radii
    • Minimum offset bend height at a given angle (90-179 deg)
  • Identifying the ideal vee die tooling
    • Vee Opening : Material Thickness ratio
    • Total tonnage required
    • Length of tooling in inventory
    • Vee Opening Angle
  • Identifying if you have enough press brake length and tonnage for a specific application
    • Which specific brakes can be used for this application
  • Guiding you to vee die tooling which will minimize operator angle corrections and increase the lifespan and performance of your tools

Who is Bend Genius For?

  • Sheet Metal Estimators & Quoters
  • Sheet Metal Designers
  • Manufacturing Engineers
  • Press Brake Operators

Sheet Metal Estimators & Quoters

Bend Genius was originally designed for the estimators in my sheet metal shop. You’re very busy, always under a time crunch to get that estimate to the customer, and you don’t always have time to nit-pick every little detail on a customer design drawing. This is where Bend Genius comes in.

With only a little training you can identify the “critical features” of a sheet metal part requiring bending. When you enter those features into the Bend Genius calculator, you’ll know immediately if this part is a no-brainer, or if you need to submit it to your Manufacturing Engineer/Bending Professional for a higher level analysis.

With Bend Genius, yes means yes, you’re safe to quote that job – and you get answers whenever you want them, even at 2 a.m., without having to wait for a response from your technical support team. If Bend Genius tells you No? – That might not really mean “no”, it means “maybe”, but you need to have your technical support review it.

Bend Genius will significantly reduce the number of times you get in a bind for quoting something that your company doesn’t have the capabilities to produce. That’s a big deal!

Sheet Metal Designers

Bend Genius will help you design it right the first time.

Open up a window of Bend Genius and populate it with the sheet metal you’re using in your design. BG will give you the technical information you need to make sure that you’re designing your components so that they are actually manufacturable the first time – and they will actually match the print! This is done using your actual machines and tooling – or the machines and tooling of your subcontractor. These values include specific vee die selection, minimum leg lengths at a given bend angle, safe distances for hole and slot deformation, minimum offset bend heights at a given bend angle, and lots more info!

Even if you have offline bend programming software, you can waste many hours designing something incorrectly before the offline programming software has an opportunity to process your components and identify the errors that you now must go back and redesign. It’s just quicker and easier to do it correctly from the beginning.

Manufacturing Engineers

I’m a manufacturing engineer like you. I designed Bend Genius so that my teammates would have a tool to allow them to reliably and repeatedly apply sound technical bending logic to their specific applications. And so they would stop chasing me down with simple questions all day long!

Once I built Bend Genius, I realize that I’m using it as much or more than any of the intended customers! BG keeps all of my machine and tooling capabilities in one place, and automatically runs the calculations I always used to do by hand, or in my head – so I don’t have to try to remember all of these things anymore. And I don’t have to worry about accidentally fat-fingering my calculator because I was rushing through my calcs.

Bend Genius knows the length and tonnage capacities of my machines, and it knows all the critical information about my vee dies, including length of tooling available and the angle of the vee opening. When BG is done running it’s calculations, it tells me exactly why the logic tests failed – then I can take a closer look and determine if I’m comfortable overriding the calculator and allowing my team to proceed with manufacturing those components.

I train my team that if Bend Genius tells them “yes”, then they can be confident we can form those parts. If Bend Genius tells them “no”, then they need to come talk to me and get a higher level technical analysis. This method has almost entirely eliminated the basic, Level 1 questions I used to get on a daily basis – now my team only brings me the real technical challenges that are much more fun for me to sink my teeth into!

Press Brake Operators

Highly educated press brake operators are rapidly becoming a rarity. Many operators have learned basic rules-of-thumb that were handed down through the years, and many of these rules are simply not correct.

Bend Genius is a very fast and very easy way for your brake operators to confirm that the tooling they want to use, or are being directed to use, is safe for their bending application.

If a flat part arrives at your brakes engineered incorrectly, the brake operator will have to make a decision when choosing a vee die that could possibly bring the parts into tolerance, and save your company the cost of re-engineering and re-cutting the components. Most operators do not have the tools necessary to choose the ideal vee die to use in this situation. Many operators have been trained to simply “lie” to their press brake controller in order to get a part to run on certain tooling.

Bend Genius will show your operators which tools are safe to use, and which tools are not. BG will help your operators see the difference in bend radius that’s likely to occur when changing vee dies, and help them choose the die that will get the parts in tolerance on the first try – instead of wasting precious time trying every tool in the drawer.



How do I Get Started?

Easy! Just send and email to CustomerService@BendGenius.com - that’s it! We’ll start a conversation to make sure we understand your needs and your application and make sure that Bend Genius is a good fit for you.


What About Training? How do I learn how to use Bend Genius?

We’re working diligently on creating some online training resources that you can show to your team. Until we get those up and running, you’ll get some 1 on 1 training with us!