{"id":9662,"date":"2026-04-14T09:00:00","date_gmt":"2026-04-14T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?post_type=case_studies&#038;p=9662"},"modified":"2026-03-26T10:12:44","modified_gmt":"2026-03-26T09:12:44","slug":"ems-sheet-metal-processing-case-study-tube-bending","status":"publish","type":"case_studies","link":"https:\/\/tps-elektronik.com\/en\/case-studies\/ems-sheet-metal-processing-case-study-tube-bending\/","title":{"rendered":"How a European Industrial OEM Solved Complex Tube Bending Challenges With TPS EMS Sheet Metal Processing"},"content":{"rendered":"<article class=\"blog-post\" lang=\"en\">\n<header>This case study describes a collaboration between TPS Elektronik and a European industrial automation OEM (name withheld) that faced critical challenges in sheet metal and tube bending for their next\u2011generation control cabinets. Through integrated EMS sheet metal processing\u2014including CNC tube bending, welding, and finishing\u2014TPS helped the client achieve higher precision, faster lead times, and a single\u2011source supply chain.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/sheet-metal-processing\/\">Request a sheet metal &amp; tube bending RFQ \u2192<\/a><\/p>\n<\/header>\n<nav class=\"toc\" aria-label=\"Table of contents\">\n<h2 id=\"toc\">Table of contents<\/h2>\n<ul>\n<li><a href=\"#overview\">Project overview<\/a><\/li>\n<li><a href=\"#challenge\">The challenge: complex tube geometries and inconsistent quality<\/a><\/li>\n<li><a href=\"#solution\">The solution: integrated EMS sheet metal &amp; tube bending capabilities<\/a><\/li>\n<li><a href=\"#results\">Project outcomes: precision, efficiency, and single\u2011source reliability<\/a><\/li>\n<li><a href=\"#faq\">FAQ: sheet metal &amp; tube bending for system integrators<\/a><\/li>\n<\/ul>\n<\/nav>\n<section id=\"overview\">\n<h2>1. Project overview<\/h2>\n<p>When a leading European industrial automation OEM needed to scale production of a new family of control cabinets with integrated cooling ducts and complex tube structures, they turned to TPS Elektronik. The client\u2019s existing suppliers struggled with inconsistent bend radii, long lead times, and the need to coordinate multiple vendors for sheet metal enclosures, tube assemblies, and welding. TPS was engaged to provide a complete EMS sheet metal processing solution\u2014from design feedback to finished assemblies.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-9646\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/03\/industrial-cnc-tube-bending-machine.jpg\" alt=\"Industrial CNC tube bending machine forming a metal tube with precision tooling, factory environment Industrielle CNC-Rohrbiegemaschine formt ein Metallrohr mit Pr\u00e4zisionswerkzeugen, Fabrikumgebung\" width=\"1408\" height=\"768\" \/><\/p>\n<p>By consolidating all metal processing under one roof, TPS eliminated the interface risks that previously caused rework and delays. This case study illustrates how integrated <strong>sheet metal processing<\/strong> can benefit system integrators and panel builders facing similar challenges.<\/p>\n<p>For a comprehensive overview of TPS sheet metal capabilities, refer to our <a href=\"https:\/\/tps-elektronik.com\/en\/custom-sheet-metal-fabrication-precision-manufacturing\/\">Custom Sheet Metal Fabrication guide<\/a>.<\/p>\n<\/section>\n<section id=\"challenge\">\n<h2>2. The challenge: complex tube geometries and inconsistent quality<\/h2>\n<p>The client\u2019s new control cabinet design required:<\/p>\n<ul>\n<li>Multiple stainless steel tubes with tight bend radii for integrated cooling channels.<\/li>\n<li>Complex 3D shapes that demanded precise <strong>cnc tube forming<\/strong> and repeatability.<\/li>\n<li>Welded assemblies with strict cosmetic and structural requirements.<\/li>\n<li>Enclosures with cutouts, threaded inserts, and powder coating that had to align perfectly with tube assemblies.<\/li>\n<\/ul>\n<p>Initially, the client worked with separate suppliers: one for sheet metal enclosures, another for <strong>tube bending machine<\/strong> work, and a third for welding. This resulted in:<\/p>\n<ul>\n<li>Inconsistent bend angles and springback across batches.<\/li>\n<li>Long lead times due to coordination delays.<\/li>\n<li>Rework caused by mismatched interfaces between enclosures and tube assemblies.<\/li>\n<li>No single point of accountability for quality documentation.<\/li>\n<\/ul>\n<p>As a result, the client faced extended project timelines and increased costs. They needed a partner with in-house <strong>cnc bending machine<\/strong> capabilities, welding expertise, and the ability to handle both sheet metal and tube processing under one quality system.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-9658\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/03\/generated_image_96d10805-1.jpg\" alt=\"Operator checking a bent tube against a CAD model on a screen, showing deviation analysis Mitarbeiter pr\u00fcft gebogenes Rohr anhand CAD-Modell auf Bildschirm mit Abweichungsanalyse\" width=\"1408\" height=\"768\" \/><\/p>\n<\/section>\n<section id=\"solution\">\n<h2>3. The solution: integrated EMS sheet metal &amp; tube bending capabilities<\/h2>\n<p>TPS Elektronik proposed an integrated approach leveraging our full EMS sheet metal processing capabilities:<\/p>\n<h3>3.1 CNC tube bending &amp; forming<\/h3>\n<p>We utilized modern <strong>cnc tube bender<\/strong> equipment capable of handling stainless steel and aluminum tubes with diameters from 10mm to 80mm. Our process included:<\/p>\n<ul>\n<li>Simulation of bend sequences to minimize scrap and validate tooling.<\/li>\n<li>Precision mandrel bending to prevent ovality and wrinkling.<\/li>\n<li>In-process dimensional checks using laser measurement.<\/li>\n<\/ul>\n<p>This allowed us to achieve consistent bend radii within \u00b10.2 mm, meeting the client\u2019s strict cooling channel requirements.<\/p>\n<h3>3.2 Sheet metal fabrication &amp; welding<\/h3>\n<p>Simultaneously, we fabricated the sheet metal enclosures using laser cutting, CNC press brake forming, and automated welding. Welding processes were selected based on material and joint type:<\/p>\n<ul>\n<li>TIG welding for stainless steel tube-to-plate joints requiring high cosmetic finish.<\/li>\n<li>MIG welding for structural frame connections.<\/li>\n<li>Robotic welding for repeatable sub-assemblies.<\/li>\n<\/ul>\n<p>For more on welding techniques, see our guides on <a href=\"https:\/\/tps-elektronik.com\/en\/mig-welding-machine-welding\/\">MIG welding<\/a> and <a href=\"https:\/\/tps-elektronik.com\/en\/mig-vs-tig-welding-key-differences\/\">MIG vs TIG welding<\/a>.<\/p>\n<h3>3.3 DFM &amp; quality integration<\/h3>\n<p>TPS provided DFM feedback during the design phase, helping the client optimize tube bend radii to use standard tooling and reduce costs. We also implemented a First Article Inspection (FAI) process covering both sheet metal and tube components to ensure interface compatibility before full production.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-9654\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/03\/generated_image_fe2ee868-1.jpg\" alt=\"Welding robot performing TIG welding on a tube-to-plate assembly in a clean manufacturing cell Schwei\u00dfroboter f\u00fchrt WIG-Schwei\u00dfen an einer Rohr-Platte-Baugruppe in einer sauberen Fertigungszelle durch\" width=\"1408\" height=\"768\" \/><\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/sheet-metal-processing\/\">Learn how integrated sheet metal &amp; tube bending can simplify your supply chain \u2192<\/a><\/p>\n<\/section>\n<section id=\"results\">\n<h2>4. Project outcomes: precision, efficiency, and single\u2011source reliability<\/h2>\n<p>By consolidating sheet metal, tube bending, and welding with TPS Elektronik, the client achieved:<\/p>\n<ul>\n<li><strong>Reduced lead time<\/strong>: 35% faster time from RFQ to finished assemblies compared to the previous multi\u2011vendor approach.<\/li>\n<li><strong>Improved quality<\/strong>: Zero interface mismatches in the first production run; all tubes and enclosures mated perfectly.<\/li>\n<li><strong>Lower total cost<\/strong>: Eliminated shipping between multiple suppliers and reduced rework.<\/li>\n<li><strong>Full traceability<\/strong>: TPS provided a complete quality package including material certificates, weld inspection reports, and FAI.<\/li>\n<\/ul>\n<p>The client\u2019s engineering team noted that the DFM feedback on tube bend radii allowed them to simplify tooling and reduce per\u2011part cost without compromising thermal performance. The success of this project led to an ongoing partnership, with TPS now handling all sheet metal and tube processing for the client\u2019s new product lines.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-9650\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/03\/generated_image_ffd1e6c3-1.jpg\" alt=\"Assembled control cabinet with integrated tube cooling system and sheet metal enclosure, final inspection Fertig montierter Schaltschrank mit integriertem Rohrk\u00fchlsystem und Blechgeh\u00e4use bei der Endkontrolle\" width=\"1408\" height=\"768\" \/><\/p>\n<p>For system integrators and panel builders, this case illustrates the value of partnering with an EMS provider that offers true one\u2011stop metal processing. Explore our dedicated <a href=\"https:\/\/tps-elektronik.com\/en\/ems-sheet-metal-processing-electronics-enclosures\/\">EMS Sheet Metal Processing for Electronics Enclosures<\/a> page for more details.<\/p>\n<\/section>\n<section id=\"faq\">\n<h2>5. FAQ: sheet metal &amp; tube bending for system integrators<\/h2>\n<div>\n<div>\n<h3>What types of tube bending machines does TPS use?<\/h3>\n<div>\n<div>We utilize CNC tube benders with mandrel bending capabilities for precise, repeatable bends in steel, stainless steel, and aluminum. Our equipment includes both rotary draw benders for tight radii and roll benders for large-diameter tubes.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>How do you ensure tube and sheet metal interfaces align perfectly?<\/h3>\n<div>\n<div>We combine DFM review with First Article Inspection (FAI). All tube bending programs and sheet metal part dimensions are verified together using a common coordinate system, ensuring that mounting holes and tube ends match exactly.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>Can TPS handle both prototype and production volumes?<\/h3>\n<div>\n<div>Yes. Our EMS model supports everything from rapid prototypes to series production. We offer the same DFM feedback, quality documentation, and tooling flexibility across all volumes.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>What certifications apply to your sheet metal processing?<\/h3>\n<div>\n<div>Our facility is ISO 9001 certified. We follow industry standards such as ISO 2768 for general tolerances and, where applicable, support medical (ISO 13485) and automotive (IATF 16949) requirements. Welding is performed per ISO 3834 or customer specifications.<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/section>\n<footer class=\"cta-footer\"><strong>Ready to simplify your sheet metal and tube bending supply chain?<\/strong> Contact TPS Elektronik for a transparent RFQ process, DFM feedback, and integrated manufacturing from prototype to series. <a href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/sheet-metal-processing\/\">Request your sheet metal processing RFQ \u2192<\/a><\/p>\n<\/footer>\n<\/article>\n\n<style id=\"wpforms-css-vars-4659-block-51e73d84-c7b8-4291-8fb4-8df1291c6c38\">\n\t\t\t\t#wpforms-4659.wpforms-block-51e73d84-c7b8-4291-8fb4-8df1291c6c38 {\n\t\t\t\t--wpforms-field-size-input-height: 43px;\n--wpforms-field-size-input-spacing: 15px;\n--wpforms-field-size-font-size: 16px;\n--wpforms-field-size-line-height: 19px;\n--wpforms-field-size-padding-h: 14px;\n--wpforms-field-size-checkbox-size: 16px;\n--wpforms-field-size-sublabel-spacing: 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Through integrated EMS sheet metal processing\u2014including CNC tube bending, welding, and finishing\u2014TPS helped the client achieve higher precision, faster lead times, and a\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/ems-sheet-metal-processing-case-study-tube-bending\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":9,"featured_media":9654,"template":"","class_list":["post-9662","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How a European Industrial OEM Solved Complex Tube Bending Challenges With TPS EMS Sheet Metal Processing - TPS<\/title>\n<meta name=\"description\" content=\"Case study: How a European industrial OEM solved complex cnc tube bending and sheet metal challenges with TPS\u2019s integrated EMS capabilities.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/ems-sheet-metal-processing-case-study-tube-bending\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How a European Industrial OEM Solved Complex Tube Bending Challenges With TPS EMS Sheet Metal Processing - 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