As we have been developing a Stratus tubing line we had a challenge brought before us this week. Our customer wanted to see if we could make a tight-radius 2" OD tube that could be sectioned together to form a circular helix.
The challenge here is the length of tubing required to make the bends. Our technique requires bending an 18′ section of tubing to get a single, tightly wound, 3-tier helix. When completed, we will need 20 sections to form the design pictured below.
With our proprietary bending technique, we construct a form with the proper diameter, and carefully roll the tubing for a tight curl.
After bending the tube, it cools on the form and is removed to cut off the tangent ends.
It is imperative that the bend remain round throughout this process for ease of coupling to other sections and for the insertion of the LED lights throughout.