CNC Tube Bending Assembly with Welded-End and Flared-End Connections – Real Case Application

Precision OEM Tube Fabrication for Fluid Transfer Systems

In industrial fluid or gas systems, the reliability of a tube assembly is essential. In this blog, we share a real case where our CNC tube bending and tube end forming services helped a customer in the hydraulic industry solve a dual-end connection challenge using steel bent tubes.

What Is CNC Tube Bending?

CNC tube bending is a modern and efficient process that uses multi-axis bending machines to form tubes into precise geometries. The CNC system ensures repeatability, tight tolerances, and minimal deformation—especially important for OEM tube fabrication and assemblies with strict dimensional requirements.

Key Benefits of CNC Tube Bending:

• Consistent, repeatable accuracy for batch production

• Complex multi-plane bending

• Tight radius capability without wrinkles or flattening

• Reduced welding joints through continuous precision bends

We provide CNC tube bending services for materials such as:

• Stainless steel

• Aluminum

• Copper

• Brass

• Carbon steel

• Titanium

Case Study: Steel Bent Tube with Welded and Flared-End Connectors

Background

One of our Canada-based clients, a manufacturer of skid-mounted hydraulic systems, required a custom bent tube with connectors for a high-pressure fluid transfer application. The key specifications included:

• Material: Steel 10#

• Outer Diameter: 16mm

• Wall Thickness: 1.2mm

• Bend Type: Z-shape with two 87° bends

• End A: Tube flared at 37°, fitted with nut ,sleeve, and threaded connector 1/2 NPT

• End B: Connector welded directly to the tube

• Surface Treatment: The final surface treatment is 3+Cr zinc plating in blue white and must pass the 72-hour salt spray test

• Required Tolerance: ±0.2mm

• Quantity: 500 sets/month

The Challenges

Their previous supplier struggled with bend consistency and connector alignment, resulting in poor sealing performance and failed pressure testing.

Our Solution

We delivered a complete OEM tube fabrication solution by:

1. Utilizing multi-axis CNC tube bending machines to form precise, repeatable geometries

2. Performing flaring on one end to create a 37° cone suitable for sealing with a nut and sleeve

3. Welding the opposite end connector using TIG welding for clean, strong joints

4. Conducting 100% pressure testing at 250 bar to ensure sealing integrity

5. Delivering the finished bent tube with connectors ready for direct assembly

The Result

• 100% pressure test pass rate

• No customer complaints in 3 consecutive batches

• Client expanded the project scope to include a second tube design

• Improved assembly speed on the customer’s production line

Where These Bent Tubes with Mixed-End Connections Are Used

• Hydraulic power units

• Pneumatic valve systems

• Skid assemblies in oil & gas

• Automotive brake and fuel lines

• HVAC equipment

• Medical and laboratory machinery

These dual-end tube assemblies—with one end flared and the other welded—are ideal for applications where space is limited and leak-free reliability is critical.

This project covers a wide range of precision tube fabrication processes, including:

• CNC tube bending

• Bent tube with connectors

• Tube end forming (flaring, welding)

• Steel tube bending

• Custom tube bending services

• Flared tube ends

• Welded tube connections

• OEM tube fabrication

• Multi-axis tube bending

• Hydraulic tube assembly

• CNC tube bending supplier in China

Learn more about our tube bending and end forming capabilities.

Why Customers Trust Us for Custom Tube Bending Projects

• 20+ years of industry experience

• Complete in-house bending, welding, flaring, and testing

• Exported to 30+ countries (Europe, North America, Oceania)

• ISO 9001 certified

• Flexible support for both prototyping and mass production

• One-stop service for tube assemblies and fittings

See More, Build Better – Contact Us Today

We support global OEMs, system integrators, and equipment manufacturers with professional CNC tube bending and connector assembly services. Whether you need small-batch custom parts or large-volume production, we deliver solutions you can rely on.

📩 Interested in our CNC tube bending services?
Visit our website: https://machiningfabtech.com
Or email us at: Cindy@machiningfabtec.com

Let’s build your custom bent tube assemblies – precisely, efficiently, globally.

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