The tube and wire measurement industry is rapidly evolving, shaped by the demand for higher precision, faster turnaround times and top-tier quality. To remain competitive in this fast-moving landscape, manufacturers must adapt and invest in cutting-edge technology. In fact, the Bending Machine Market is projected to grow by USD 2.48 billion from 2025 to 2029, driven by innovations in robotics and bending technologies. This growth is a sign of the increasing need for speed and accuracy in tube bending operations.
Let’s take a look at how you can optimise your tube bending operations, improve efficiency and guarantee top-quality products.
1. Invest in advanced measurement technologies
The latest advancements in measurement systems are changing the game. To meet the increasing demand for faster and more precise production, it’s crucial to upgrade your inspection technologies. Solutions like TubeInspect offer highly accurate, ultra-fast inspection capabilities, compensating for environmental changes like temperature variations to ensure consistent accuracy.
Evaluate your current measurement systems and identify areas for improvement. Automated measurement systems, for example, can eliminate manual inspections, speeding up production and ensuring consistent quality. With real-time feedback and integration with your bending machines, you’ll reduce errors and maintain high standards while boosting production efficiency.
TubeInspect: A turnkey non-contact optical measurement cell for tube and wires
2. Automate your production line for efficiency
Automation is the key to optimising modern manufacturing processes. With automation, you can reduce human error, improve throughput and deliver higher consistency across production runs. For industries like electric mobility, where precision bending of tubes for components such as hairpins and busbars is crucial, advanced measurement and bending technologies are becoming a must-have.
Take TubeInspect as an example. It’s designed to work with your automated systems, connecting directly to bending machines for seamless integration. This means fewer manual adjustments and more time spent on productive tasks. The result? Reduced scrap rates, faster cycle times and improved product quality. One example from WTX highlights this well: by integrating automated tube inspection, they slashed series changeover time from 120 minutes to just 30, while reducing defects to under 0.5 PPM, leading to higher customer satisfaction.
The upfront cost might seem steep, but the ROI is undeniable. Faster production cycles, reduced waste and improved accuracy all contribute to a more efficient bottom line.
TubeInspect can be seamlessly integrated into automated lines and workflows
Numalliance integrates TubeInspect in their production cells to create fully automated tube production-inspection-correction loops
3. Ensure seamless integration with existing systems
As tube bending operations get more sophisticated, smooth integration of your systems is critical. Whether it’s connecting CNC machines to bending equipment or ensuring your measurement systems work seamlessly with your production lines, integration can make or break your efficiency.
Tools like BendingStudio XT offer a platform that connects your production, quality control and design teams. It supports the full production cycle, providing real-time updates and allowing for instant corrections, meaning no unnecessary delays or downtime. Additionally, by adopting a cloud-based system like Metrology Asset Manager, you can monitor your system’s health from anywhere, ensuring you stay ahead of issues and make data-driven decisions quickly.
BendingStudio XT is a central software hub that links all Hexagon tube and wire measurement tools into one connected system. It handles everything from real-time analysis to bender corrections, combining design, production, and quality control in a single solution.
4. Adapt to environmental and operational changes
In production sites, environmental factors such as temperature fluctuations, oil and dust can stress machinery and workers, leading to equipment breakdowns and reduced productivity.
TubeInspect is designed to be used even in harsh production environments. It adjusts to temperature fluctuations automatically, ensuring your measurements remain accurate regardless of ambient conditions.
Make sure your measurement systems can handle these environmental variables. With built-in temperature compensation features and ISO 17025 certified calibration, a system like TubeInspect guarantees high-quality results no matter the setting, giving you the confidence that your operations won’t be interrupted by external conditions.
Future-proof your tube bending operation
By embracing technological advancements and automation, you can significantly improve the precision, speed and overall quality of your tube bending operations. Integrating high-tech bending and measurement systems, automating processes, ensuring system compatibility and factoring in environmental changes are all steps you can take to boost your efficiency and stay ahead in a competitive market.
Ready to take your tube bending operations to the next level? Contact us to see how our solutions can streamline your production line and keep you at the forefront of the industry.
