Plan the part before you cut the tube. Bend Genie helps you work out the developed cut length, locate the bends, organize bend angles and review the shape before moving to the machine. For handrails, frames and other bent tube or pipe parts, it brings the layout information together instead of leaving the operator to reconstruct the job from scattered measurements.
Bend Genie is included free with an Ercolina purchase. Ask CML USA to arrange the included access with your machine purchase and explain activation. This purchase benefit is separate from the public 30-day trial advertised for customers exploring the software. Contact CML USA for the access details associated with your order; do not assume a trial signup automatically activates the purchase benefit.
What does tube-bending layout software help you determine?
- How long to cut the blank: Prepare a developed-length reference based on the part geometry, bend radii and selected settings rather than simply adding the outside dimensions of the finished part.
- Where the bends begin: Use flat layouts and bend-location references to communicate the relationship between straight sections and bends. Confirm whether the drawing and shop setup use start, center or end-of-bend references.
- How many bends the design contains: Build and review the bend sequence so the operator can identify each bend. The software supports your chosen geometry; it does not independently decide the correct design or minimum bend count for every application.
- The angle for each bend: Organize the specified bend angles and consider springback compensation before setup.
- Rotation between bends: For parts that change bending planes, length-rotation-angle data helps communicate the orientation as well as the bend itself.
- How the part should look: Review the shape in 3D and use dimensioned prints or shop reports to make the handoff clearer.
Why the correct cut length matters
A bent part contains both straight lengths and curved sections. Bend radius and angle affect how much stock is required, and the actual material and tooling can affect the result. Guessing the blank length from finished outside dimensions can create unnecessary trimming or leave a part too short.
Bend Genie provides flat-layout and cut-length references, with material and stretch settings available for refinement. Treat the result as a planning value to validate using your actual material and process. Include any required clamping length, trim allowance or end preparation in the approved production plan; do not assume every job-specific allowance is automatically included.
Make bend locations and angles easier to communicate
Two operators can read the same dimension differently if one measures to the start of a bend and another measures to its center. Bend Genie supports start, center and end references, helping your team establish a consistent way to read the job.
In LRA—length, rotation and angle—each bend is part of an organized sequence. Check that the software’s reference conventions match the machine setup, stops and production drawing. A layout dimension is not automatically a physical mark or machine-feed value without that check.
A practical workflow: drawing to first part
- Enter the stock information. Select the material and section, including actual outside diameter and wall thickness. Pipe nominal size is not its outside diameter.
- Choose suitable tooling. Use documented Ercolina tooling or a verified custom entry and the intended centerline radius. Confirm the machine’s material and tooling limits.
- Create or review the geometry. Build the part with the available layout tools or LRA/XYZ workflow. Check overall dimensions, straight lengths, bend count, angles and rotation.
- Inspect the 3D shape and layout. Review bend locations, reference directions and the sequence. Software checks are useful aids, not proof that the real workpiece will clear every machine component.
- Prepare the blank and job information. Use the validated cut length and any approved allowances. Cut, inspect, deburr and clean the tube, then provide the operator with the layout and setup information.
- Make and inspect the first part. Confirm springback, dimensions and fit with the actual material and tooling. Adjust the approved process before producing the batch.
- Save the proven job. Keep the part, settings and relevant shop notes for future runs. Check them again when material, tooling or equipment changes.
A useful free tool alongside a Top Bender or Super Bender
Bend Genie complements machines such as the Ercolina TB60-TC Top Bender and SB48-TC Super Bender. The software helps prepare and communicate the part; the bender’s controls and tooling carry out the approved bending operation.
It does not turn a manually positioned workflow into fully automatic CNC feeding and rotation. Export availability and direct machine handoff depend on the controller and configuration. Ask CML USA to demonstrate the exact workflow you will use rather than assuming a saved software file can run on every machine.
Handrails, frames and repeat fabrication
For handrails, a clear layout helps coordinate straight sections, corners, returns and changes of plane. Bend Genie’s templates provide starting points for handrail and other common fabrication layouts; enter the actual job dimensions and verify the finished design against the drawing and applicable requirements.
A Pedrazzoli Super Brown cold saw can prepare the validated blanks, while an Ercolina EN100 notcher can prepare suitable mating ends. Software, saw, bender and notcher each address a different part of the workflow.
Explore the cold-saw preparation guide and EN100 handrail production guide for the physical preparation steps.
Browser-based planning without a desktop installation
Bend Genie runs in a browser and can be accessed from Windows, Mac, tablet or phone. Its documented features include 3D visualization, LRA/XYZ data, material and tooling libraries, saved parts, inch/metric conversion, dimensioned prints and supporting exports. A larger screen can make detailed part review easier.
Use springback estimates and compatibility checks as starting points. They do not replace machine-capacity checks, operator training, safe setup or first-piece inspection.
Frequently asked questions
Is Bend Genie free when I buy an Ercolina?
Yes. Bend Genie is included free with an Ercolina purchase. Ask CML USA to arrange your included access and explain the activation details for your order. The separate public trial is intended for evaluating the software.
Can it tell me where to bend and how long to cut the tube?
It provides cut-length and bend-location references based on the geometry and settings you enter. Confirm the dimension conventions, material behavior and any required clamping or trim allowance before releasing blanks for production.
Does it show the number and angle of the bends?
You can build and review the part’s bend sequence, including its bend count, angles and rotations. You remain responsible for selecting and approving the part geometry and a workable production sequence.
Does it remove the need to check springback?
No. Estimates help plan the setup, but actual springback depends on material, tooling and process conditions. Validate the first part and record the approved compensation.
Can I try it before buying a machine?
The public Bend Genie site currently offers a 30-day trial. Visit Bend Genie’s feature overview to explore the software and trial options. Existing purchasers should contact CML USA about their included access rather than assuming they need a separate paid subscription.
Get more from your Ercolina purchase
A free layout tool is most useful when it becomes part of your normal job preparation. Start with one real part, review the cut length and bend sequence, and prove it with your shop’s equipment. Then reuse the approved information rather than starting from scratch on every repeat order.
Ask CML USA about an Ercolina machine and included Bend Genie access, or read the Ercolina tube-bending software overview.