Double Head Tube Bending Machines — DuralBend Gemini Series

Here’s the thing about double head pipe bending machines — once you start using one, going back to a standard single-head setup feels painfully slow. A twin head tube bender cuts cycle times dramatically compared with a conventional mandrel type machine, because both ends of a symmetrical part are bent in the same pass instead of one after the other. That isn’t a marketing claim; it is what our customers report from the shop floor.

DuralBend has been building double head pipe bending machines since 2008. The current Gemini series is the result of all those years of refinement.

The Gemini Range

We currently offer three models in the double head tube bender lineup. Each one is aimed at a different level of automation and production requirement, so here is a walk through all three.

Gemini B38 — The Workhorse

This is the entry point into twin head pipe bending. The Gemini B38 is a fully hydraulic double head pipe bender with NC control and a monoblock frame. Linear guide pressure die, tension arm, magnetic stopper, touchscreen with multi-language support — it is all there. Auto and manual mode, quick tooling changeover. 7.5 kW total power, max Ø38 mm x 2 mm, bending up to 185°. A straightforward machine that does what it is supposed to do very well.

For a basic double head tube bending machine it is a seriously reliable workhorse.

Gemini BF38 — Semi-Automatic, Servo Controlled

The BF38 steps it up. Same monoblock body and hydraulic bending as the B38, but with 2-axis servo control added on top. The curvature axis uses inverter control for smoother bends, and there is a PLC with NC capability. It still has the foot pedal option for manual work, which some operators prefer for certain jobs. Total power goes to 11.5 kW, with the same Ø38 mm x 2 mm capacity and 185° range.

The difference is consistency. If you’re running production volumes where repeatability across hundreds of pieces matters, the Gemini BF38 double head tube bender is the better pick.

Gemini BFR38 — Full CNC, 6-Axis Servo

This is the newest addition to the Gemini family and it is a significant step for the double head pipe bending machine category. The BFR38 is a fully automatic, 6-axis servo driven twin head tube bending machine with full CNC software. Every single axis is servo controlled — bending, feeding, rotation, everything.

There is one important thing to know: the BFR38 bends single tubes only. It does not run multiple tubes simultaneously the way the other two models can. What it does do is bend that single tube with full CNC-level precision and programmability. You get simulation, 3D CAD import and the whole software package that you would normally only find on our standalone CNC pipe bending machines. Very few machines on the market combine full CNC control with a double head platform, so if your application needs complex multi-bend geometries in that format, this is the one to look at.

What Can You Actually Bend?

The Gemini B38 and BF38 are flexible when it comes to tube capacity. In a single cycle they handle:

• 1 tube at Ø38 mm x 2 mm
• 2 tubes at Ø25 mm x 1.5 mm simultaneously
• 3 tubes at Ø16 mm x 1.5 mm simultaneously
• 4 tubes at Ø13 mm x 1.5 mm simultaneously

Up to four tubes at once on a double head pipe bender — four small diameter bends in one cycle instead of one at a time on a regular tube bending machine. The arithmetic speaks for itself.

As noted above, the BFR38 works with single tubes only, but it brings CNC level control to the double head tube bending machine format.

Why Go Double Head?

A standard pipe bending machine works fine for a lot of jobs. But if you’re making symmetrical parts — chair frames, handlebars, exhaust components — a double head tube bender does it in one pass. No flipping, no re-clamping. Less handling means fewer errors and much faster cycle times. For high volume symmetrical bending there is really no argument against a twin head pipe bending machine.

All three Gemini models come with quick-change tooling, energy saving mode, a monoblock frame and multi-language touchscreen controls. The complete list is in the Standard Features tab below.

Talk to Us About Your Part

Send us your component drawing or a sample frame and we will tell you which Gemini model fits. Email info@duralbend.com or call +90 212 482 41 07.