Automated Press Brake Cell (Metazet)

Thijs van Strien | Fabian Molenaar | Hedda Auråker | Rens Oldenburger

A prototype demonstrating fully automated bending of end caps without manual handling.

Date: 14.04.2026

Metazet announces the development of a prototype automated press brake cell using a collaborative robot. The system automates the process of bending metal sheets into end caps used for greenhouse gutters.

The goal of the project is to eliminate manual handling in the bending process. The prototype demonstrates a complete bending cycle from input of raw metal sheets to finished end caps placed in an output bin.

Problem

• Manual and repetitive work
  The current workflow requires continuous operator involvement, reducing efficiency and increasing labour costs
• No vision system allowed
  Due to unstable lighting conditions, the system must operate without cameras or vision-based alignment
• Press brake communication uncertainty
  The press brake is supplied by an external manufacturer, making signal integration complex
• Removable setup requirement
  The system must be installed and removed within 5 minutes, as the press brake is also used for manual operations

Current Workflow

In the current production process:

1. Metal sheets are laser cut and placed randomly in a bin
2. The bin is positioned near the press brake
3. An operator manually adjusts machine settings and tools
4. The operator bends all four sides using a foot pedal
5. Finished parts are placed manually in an output bin

This process is repetitive, time-consuming, and highly dependent on manual labour.

Solution

The developed prototype addresses these challenges through a combination of mechanical design and simplified system architecture:

• Automation of the full workflow
  The robot performs all handling steps from input to output, eliminating manual intervention
• Mechanical positioning instead of vision
  A gravity canvas ensures consistent orientation of the metal sheets without cameras
• Simplified press brake communication
  A wired signal triggers the bending cycle, combined with a deadman switch for safe operation
• Flexible and removable setup
  A lock-in system ensures precise positioning while allowing fast installation and removal

How the System Works

1. The operator places metal sheets in a structured input bin
2. The input and output bins are positioned in fixed locations
3. The system is started via a Python script connected to the robot
4. The robot picks a metal sheet from the input bin
5. The metal sheet is aligned using a gravity canvas
6. The robot loads the metal sheet into the press brake
7. The press brake performs bending (4 cycles per part)
8. The robot transfers the finished end cap to the output bin

A manual quality check is performed on the first part in each batch before continuing production.