TUBE & PIPE
BENDING
Software-designed tube assemblies bent to exact specification. We bend up to 2" Schedule 160 pipe — a capability virtually unmatched in the region — and manufacture complete hydraulic tube assemblies from design to pressure test.
DESIGNED IN SOFTWARE.
BENT TO PERFECTION.
Most tube bending shops work from hand sketches or sample parts. Mercury Hydraulics uses dedicated tube assembly design software to model your entire routing in 3D before a single bend is made. This means your assembly fits correctly the first time — no trial-and-error, no wasted material, no rework.
Our software generates the exact bend data — bend angle, rotation, and distance between bends — which is fed directly to our bender. The result is consistent, repeatable accuracy across every piece in a production run.
We can design complete tube assemblies from scratch, duplicate existing assemblies from a sample, or work from your CAD drawings. We handle the full process from design to pressure-tested finished assembly.
BENDING CAPABILITIES
General Capabilities
Materials We Bend
What Makes 2" Schedule 160 So Difficult?
Schedule 160 pipe has an extremely thick wall — on 2" nominal pipe, the wall thickness is 0.344 inches. This is nearly twice the wall of standard Schedule 40 pipe. Bending this material requires enormous force, specialized tooling, and mandrel support inside the pipe to prevent collapse and ovality at the bend. Most shops simply don't have the equipment or the experience. We do — and we've been doing it for defense and industrial customers for decades.
APPLICATIONS
Hydraulic System Plumbing
Complete hydraulic tube assemblies for high-pressure systems — designed in software, bent to exact specifications, and fitted with the correct end connections for leak-free installation.
Marine & Shipyard
Seawater-resistant stainless tube assemblies for hydraulic steering, stabilizer systems, and deck equipment. We understand marine environments and specify materials accordingly.
Aerospace & Defense
High-pressure tube assemblies for ground support equipment, test stands, and defense systems. Our DoD heritage means we understand the documentation and quality requirements.
Industrial Equipment
Replacement tube assemblies for presses, injection molding machines, and heavy industrial equipment. We can reverse-engineer worn or damaged assemblies from samples.
Custom Fabrication
One-off custom tube assemblies designed from scratch — from a sketch, a sample part, or a set of dimensions. We design it in software, verify the routing, then bend and fit.
Emergency Replacement
Burst or damaged tube assembly? We can reverse-engineer and replace it same-day for local customers. Ship us the damaged assembly and we'll duplicate it exactly.
FROM DESIGN TO DELIVERY
Design & Engineering
We use tube assembly design software to model your routing in 3D before a single bend is made. This eliminates interference issues, ensures correct bend radii, and produces a cut list and bend program that guarantees the assembly fits correctly the first time.
Material Selection & Cut
We select the correct material specification for your application — pressure rating, corrosion environment, and end connection type. Tube is cut to precise length from our material stock.
Precision Bending
Our bender uses the programmed bend data to execute each bend with consistent, repeatable accuracy. For heavy-wall pipe like Schedule 160, we use mandrel bending to prevent wall thinning and ovality at the bend.
End Preparation & Fitting
Tube ends are deburred, faced, and prepared for the specified end connection — flare, bite-type, weld, or threaded. Fittings are installed and torqued to specification.
Pressure Test & Inspection
Completed assemblies are pressure-tested to confirm integrity. For hydraulic system assemblies, we test to 1.5× working pressure. Documentation is available for defense and aerospace customers.
Related Services
NEED A CUSTOM TUBE ASSEMBLY DESIGNED FROM SCRATCH?
Our SolidWorks CAD team designs complex multi-bend tube assemblies in 3D — with clash detection, bend simulation, and direct export to our CNC tube bender. No drawings needed.
NEED A TUBE ASSEMBLY BUILT?
Send us your DXF, a sample part, or just call with your dimensions. We'll design it in software, bend it right, and have it pressure-tested and ready.