SD Industries Expands In-House Metal Forming with 350-Ton Ermaksan Falcon Press Brake
- SD Industries
- May 21
- 9 min read
SD Industries continues to expand its in-house fabrication capabilities with the addition of a 350-ton Ermaksan Power-Bend Falcon Press Brake at our Texas manufacturing facility in Conroe, Texas.
The new press brake adds a major metal-forming capability to SD Industries' manufacturing operation, allowing our team to bend and form sheet metal and plate components with the power, control, accuracy, and repeatability required for demanding fabrication applications.
With 350 tons of forming capacity, the Ermaksan Falcon provides SD Industries with the ability to handle a wide range of metal-forming requirements—from precision bends on architectural components to heavy-duty forming for structural and miscellaneous metal fabrication.
The machine complements our existing laser cutting capabilities, including our Bodor P4 Flat Laser, allowing SD Industries to cut flat material in-house and then form those components into finished shapes without depending entirely on outside forming suppliers.
What Is a Press Brake?
A press brake is a CNC-controlled metal-forming machine used to bend flat sheets and plates into precise angles and shapes.
The process works by positioning a metal component between specialized tooling and applying controlled forming force to create the required bend.
Unlike cutting equipment, which removes material, a press brake changes the shape of the material.
This makes press brakes essential for manufacturing products and components such as:
Brackets
Channels
Covers
Panels
Frames
Angles
Enclosures
Plates
Structural components
Architectural metal components
Custom fabricated assemblies
The Ermaksan Falcon takes this process to a high-capacity production level, giving SD Industries another important tool for producing complex fabricated components in-house.
Introducing the 350-Ton Ermaksan Falcon
The Power-Bend Falcon is a hydraulic CNC press brake from Ermaksan designed to combine high forming force with controlled, repeatable bending.
The Falcon series is available in a broad range of configurations, with published capacity options from 40 to 600 tons and bending-length options from 1 to 6 meters, depending on the selected model. The series is designed for both individual precision bending operations and complex multi-bend production work.
Our 350-ton Falcon brings substantial forming power to SD Industries' Texas manufacturing operation.
This capability is particularly valuable when a fabrication project requires heavier-gauge material, larger components, repeated bends, or complex formed shapes.
350 Tons of Bending Power
The biggest advantage of this machine is its 350-ton forming capacity.
A higher-capacity press brake gives SD Industries the ability to tackle demanding forming applications that may require significant force to bend thicker or stronger materials.
The required tonnage always depends on factors such as:
Material type
Material thickness
Bend length
Bend angle
Tooling
Inside bend radius
Part geometry
Because of these variables, our fabrication team evaluates the material and geometry of each component before determining the appropriate bending process and tooling.
The result is a controlled approach to metal forming rather than simply applying maximum machine capacity to every job.
CNC-Controlled Precision Bending
The Ermaksan Falcon uses CNC control to coordinate bending operations and machine positioning.
The Falcon series includes a standard Y1, Y2, X, and R four-axis configuration, supporting controlled ram movement and backgauge positioning for precision bending operations.
This allows SD Industries to program and repeat bending sequences for components requiring:
Single bends
Multiple bends
Sequential bends
Repeated production parts
Complex profiles
Consistent bend locations
CNC-controlled positioning can help reduce manual layout and improve repeatability from one fabricated component to another.
Motorized Crowning for Consistent Bends
The Falcon series also offers a motorized crowning system designed to compensate for natural machine deflection during bending.
On long or heavy workpieces, a press brake can experience slight deflection under load, which can result in different bend angles near the center and ends of a part.
Ermaksan's motorized crowning system compensates for this effect and helps produce more consistent bend angles across the length of the component. The system is integrated with the CNC control and automatically adjusts the crowning according to the bending parameters.
For SD Industries, this capability is particularly valuable when producing larger components where consistency across the entire bend length matters.
Designed for Complex Bending Operations
A modern press brake is capable of much more than creating a simple 90-degree bend.
The Ermaksan Falcon can support fabrication involving multiple bends and complex part geometry.
Depending on the material, tooling, and machine configuration, SD Industries can produce components with:
Multiple sequential bends
Different bend angles
Formed channels
Return flanges
Custom profiles
Brackets
Z-shaped components
U-shaped components
L-shaped components
Box-like forms
Enclosures
Structural formed parts
Architectural profiles
This flexibility allows flat laser-cut components to be transformed into three-dimensional fabricated parts.
From Flat Sheet to Formed Component
One of the biggest advantages of adding the press brake to SD Industries' in-house manufacturing capability is how it works together with our laser cutting technology.
A typical production workflow can now look like:
Digital Design
↓
Engineering & Detailing
↓
Bodor P4 Flat Laser Cutting
↓
Ermaksan Falcon Press Brake Forming
↓
Laser / MIG / TIG Welding
↓
Assembly
↓
Finishing
↓
Quality Control
↓
Finished Component
This integrated workflow allows SD Industries to take flat sheet metal and transform it into finished three-dimensional components within our manufacturing operation.
What Can SD Industries Produce With the 350-Ton Press Brake?
The new press brake expands the range of products and components SD Industries can manufacture in-house.
Guardrails & Handrails
Pressed and formed components can be used for brackets, mounting plates, connection components, supports, profiles, and custom elements used in guardrail and handrail systems.
These formed components can then be welded or assembled with tube, plate, glass, or other fabricated materials.
Bollards
The press brake can support the production of formed sheet and plate components used in bollard bodies, covers, mounting components, reinforcement parts, and custom protective assemblies.
Canopies
Canopies and architectural structures often require formed plates, brackets, connection components, fascia pieces, and custom profiles.
The Falcon can form these components after they have been precision cut on the Bodor P4.
Fencing & Gates
Custom fencing and gates can incorporate formed panels, brackets, channels, frames, mounting components, reinforcement pieces, and decorative elements.
Metal Staircases
Stair systems can require numerous formed components, including brackets, supports, connection plates, pans, channels, and custom structural elements.
The 350-ton press brake gives SD Industries additional capacity for producing these formed components.
Stair Railings
The machine can support formed brackets, mounting plates, connection components, support elements, and architectural details used in stair railing systems.
Cladding
Metal cladding often involves bent panels, returns, edges, corners, transitions, mounting components, and custom profiles.
Precision bending is essential for maintaining consistent geometry across architectural panels.
The Falcon provides SD Industries with an in-house solution for forming these components after laser cutting.
Roofing Components
Many roofing applications require formed sheet-metal parts, edges, flashing-related components, brackets, transitions, and custom profiles.
These can be laser cut and then formed according to project requirements.
Escalator & Elevator Enclosures
Custom enclosures may require panels with multiple bends, returns, edges, and formed details.
The press brake can provide the controlled bending required to convert flat material into finished enclosure components.
Ticket Booths
Ticket booths and similar fabricated structures can include formed walls, panels, covers, brackets, channels, and custom components.
The Falcon can support the bending stage after flat components have been precision cut.
Signage & Sign Components
Signage packages often require bent faces, returns, cabinets, frames, mounting components, brackets, and custom sheet-metal profiles.
Laser cutting combined with CNC forming allows SD Industries to produce these components as part of an integrated fabrication workflow.
Custom Architectural Metalwork
Architectural fabrication frequently involves custom shapes and non-standard dimensions.
A programmable press brake gives SD Industries the flexibility to produce one-off components as well as repeat production parts while maintaining consistent bend locations and angles.
Structural & Miscellaneous Metals
For structural and miscellaneous metal packages, the press brake can produce formed plates, channels, brackets, stiffeners, supports, connection components, and custom profiles.
This expands SD Industries' ability to provide complete fabricated packages rather than supplying only flat-cut components.
Supporting Both Custom and Production Work
The 350-ton Ermaksan Falcon is valuable for both custom fabrication and repeat production.
Custom Components
For one-of-a-kind architectural or project-specific parts, CNC-controlled forming provides repeatable positioning and programmable bend sequences.
Small Production Runs
For dozens or hundreds of components, the same programmed process can be repeated to maintain consistency.
Large Production Packages
For larger fabrication packages, CNC forming helps standardize production and reduce variation between components.
Complex Multi-Bend Parts
Projects involving several bends or multiple angles can benefit from programmable CNC sequencing.
Why In-House Bending Matters to Customers
Bringing the 350-ton press brake into SD Industries' own manufacturing operation provides several practical benefits.
More Control Over Production
SD Industries can directly manage the forming operation instead of relying entirely on an outside bending supplier.
Better Coordination
Laser cutting, forming, welding, and assembly can be coordinated within one fabrication workflow.
Greater Design Flexibility
Our team can work with custom geometries and project-specific bending requirements.
Repeatable Results
CNC-controlled positioning helps produce consistent bend locations and repeat production components.
Reduced Outside Processing
Components can move from laser cutting directly into in-house forming, reducing unnecessary external fabrication steps.
Better Project Scheduling
Keeping more manufacturing processes within our own facility can improve coordination between different stages of production.
Integrated Quality Control
Components can be reviewed throughout the cutting, forming, welding, and assembly process rather than being transferred between unrelated suppliers.
Laser Cutting + Press Brake Forming
The combination of our Bodor P4 Flat Laser and Ermaksan Falcon 350-Ton Press Brake creates a powerful sheet-metal manufacturing workflow.
For example:
Step 1 — Laser Cutting
A flat metal sheet is cut on the Bodor P4 according to the approved digital design.
Step 2 — Deburring & Preparation
The cut component is prepared for forming.
Step 3 — CNC Positioning
The component is accurately positioned on the Ermaksan Falcon.
Step 4 — Bending
The 350-ton press brake applies controlled forming force to create the required angles and geometry.
Step 5 — Additional Fabrication
The formed component can move into welding, assembly, finishing, or other downstream processes.
Step 6 — Quality Control
The completed component is inspected according to project requirements.
This creates a connected path from flat raw material to finished fabricated product.
Designed for Heavy-Duty Metal Forming
With a 350-ton capacity, the Ermaksan Falcon gives SD Industries a strong platform for demanding metal-forming work.
The machine is especially useful when the project involves:
Heavier-gauge sheet or plate
Longer bends
Multiple bend sequences
Structural components
Large brackets
Formed channels
Architectural profiles
Custom enclosures
Heavy miscellaneous metal fabrication
The actual bendable thickness and maximum part dimensions depend on the material, bend length, tooling, geometry, and the specific machine configuration, so SD Industries evaluates each project individually.
Safety and Operator-Focused Design
The Power-Bend Falcon incorporates safety features designed specifically for press brake operation.
Ermaksan lists specialized laser safety systems for the Falcon series to help protect operators during machine operation. The system is part of the machine's overall safety architecture.
The Falcon also uses a hydraulic system and CNC control architecture designed to combine high forming power with controlled operation and repeatable production.
Integrated With SD Industries' Manufacturing Technology
The Ermaksan Falcon becomes even more valuable when combined with SD Industries' other in-house equipment.
Bodor M3 Tube Laser
For precision cutting of round, square, rectangular, and other tube and pipe components.
Bodor P4 Flat Laser
For precision cutting of flat sheet and plate components.
Ermaksan Falcon 350-Ton Press Brake
For controlled bending and forming of sheet metal and plate.
Laser Welding
For precision welding of fabricated components.
MIG Welding
For structural and miscellaneous metal fabrication.
TIG Welding
For applications requiring controlled and clean welding.
Gang Band Saw
For accurate cutting of bars, tubes, and profiles.
Together, these machines create a more complete manufacturing platform for SD Industries' architectural, structural, miscellaneous metal, signage, and custom fabrication work.
From Engineering to Fabrication
The machine is also integrated into SD Industries' broader engineering and digital fabrication workflow.
Projects can begin with:
Architectural Drawings
Structural Drawings
CAD Files
3D Models
BIM Data
Shop Drawings
Fabrication Drawings
From there, our team can develop fabrication-ready information that defines:
Material
Part dimensions
Bend locations
Bend angles
Forming sequence
Tooling requirements
Welding requirements
Assembly requirements
This connection between engineering, detailing, CNC cutting, and CNC forming helps ensure that the finished component reflects the approved project design.
Ideal Applications for the Ermaksan Falcon
SD Industries' 350-ton press brake is well suited for projects involving:
Architectural Metal Fabrication
Structural Steel Components
Miscellaneous Metals
Cladding Components
Canopies
Guardrails & Handrails
Stair Systems
Fencing & Gates
Bollards
Signage Components
Elevator & Escalator Enclosures
Ticket Booths
Custom Sheet Metal
Formed Plates & Brackets
Custom Metal Assemblies
Production Fabrication
Whether you need a single formed component, a custom prototype, or a large production package, SD Industries can evaluate the material, geometry, and production requirements to determine the appropriate forming process.
A Complete Fabrication Partner
The addition of the Ermaksan Falcon strengthens SD Industries' ability to provide more complete fabrication solutions from a single manufacturing partner.
Our capabilities can support:
Engineering
Architectural Design
3D Modeling & BIM
Scan-to-Detail Design
Shop & Fabrication Drawings
CNC Laser Cutting
CNC Forming
Laser Welding
MIG Welding
TIG Welding
Assembly
Finishing
Project Management
Quality Control
This integrated approach helps customers move from design and engineering through manufacturing and finished fabrication with better coordination and production control.
Ready for Your Next Metal Forming Project?
Whether you need precision-bent brackets, formed panels, architectural components, structural parts, custom enclosures, channels, plates, or complete fabricated assemblies, SD Industries can evaluate your requirements and develop a manufacturing approach.
Send us your:
Drawings
CAD Files
3D Models
Shop Drawings
Material Specifications
Material Thickness
Part Dimensions
Bend Requirements
Quantities
Project Requirements
Our team can review the geometry and determine how our 350-ton Ermaksan Falcon, Bodor laser technology, welding equipment, and other in-house capabilities can support your project.
SD Industries Texas Manufacturing Facility
213 Porter Road
Conroe, TX 77301
SD Industries Corporate Headquarters
250 Pehle Ave, Suite 200
Saddle Brook, NJ 07663
212-348-8000
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