Custom Tube Profiles and New Tube Sizes

We use a cold-forming process to produce non-circular tube profiles from standard circular tubing. This highly flexible manufacturing method enables us to develop new tube sizes and custom geometries quickly, whether for a prototype, a short production run or a long-term OEM programme.

Because the process does not depend on the large minimum order quantities typically associated with extrusions or dedicated roll-forming lines, new profiles can be developed with low commercial risk. The same process scales directly into repeat production, giving a straightforward route from concept to volume manufacture.

When is new tooling required? 

New tooling may be needed when a requested profile falls outside our established size range, it exceeds proven forming ratios, it requires unique radii or has dimensional requirements that existing tooling cannot achieve.

However, many bespoke dimensions can be produced by adapting current tooling, which reduces both development costs and lead times.

The most common profiles we are develop are elliptical oval and flat-sided oval (FSO) tubes.

The feasibility of a new profile depends on several factors, including the starting tube diameter, wall thickness, required dimensions and the ratio between the major and minor axes.

Oval tube is a smooth, continuous elliptical profile with no flat sections. The curve runs uninterrupted around the entire perimeter of the tube.

We currently own tooling that enables us to manufacture oval (elliptical) tubes from 23.5mm to 200mm on the major axis.

Achievable dimensions depend on the raw material, wall thickness and required profile ratio.

For most applications, we recommend keeping elliptical oval profiles below a 2:1 ratio. Beyond this point, appearance, tooling constraints and forming behaviour may require additional consideration. As the ratio between the major and minor dimensions increases, elliptical profiles can become increasingly elongated, causing the end radii to tighten and the profile to appear pointed or eye-shaped.

We have successfully manufactured elliptical profiles at ratios up to 2:1, although most standard production sizes fall below this. If your design exceeds this guideline, please contact us to discuss feasibility.

Flat-sided oval tube incorporates parallel flat faces joined by radiused ends. Flat-sided oval profiles are frequently specified as an alternative to circular tube, rectangular box section or solid bar.

We currently own tooling that enables us to manufacture flat-sided oval tubes from 16.9mm up to 200mm major axis.

Many custom sizes can be produced within this range, reducing development costs and shortening lead times (compared with commissioning an entirely new forming tool).

Achievable dimensions depend on the raw material, wall thickness and required profile ratio.

 Flat-sided oval profiles behave more predictably during forming and can comfortably exceed the ratios normally associated with conventional elliptical profiles.

New profile development is not simply a tooling exercise. Material behaviour, wall thickness, forming ratio and springback all influence the final dimensions achieved during production.

For this reason, wider tolerances apply during the first production run of a new size while the forming process is validated and repeatability is established.

Once the profile has been proven and approved, repeat production is manufactured to our standard production tolerances.

Small dimensional changes can significantly influence appearance, stiffness, bendability, fixing methods and compatibility with standard components. Early discussion with our engineering team can often improve manufacturability and reduce development costs.

Developing a new tube profile is only one part of creating a finished tubular component. Many applications also require secondary fabrication processes such as tube bending, flaring, expansion, reduction or laser cutting.

Achieving the required bend radius while maintaining profile integrity may require dedicated bending tooling, particularly for non-circular tube sections. End-forming operations may also be required to create critical interface dimensions or compatibility with standard fittings and assemblies.

Timeless Tube offers a range of fabrication services including tube bending, end forming, laser cutting and welding. Visit our tube bending guide to learn more about bending methods, tooling development and achievable bend radii.

Where fitment, bend performance or dimensional requirements are critical, we recommend discussing the application with one of our engineers at an early stage of the project.