Horn-type punches are specialized bending tools featuring milled recesses. They are primarily used when bending closed shapes, such as boxes, covers, or enclosures. In the following article, you will learn in detail how they work and when they become indispensable.

Why the Name “Horns”?

The term horns comes from the distinctive shape of the outer sections of these punches. These end segments often resemble small protruding “horns.”
Depending on the geometry of the bent part, these segments can also be inward-facing, especially during more complex bends where previously formed flanges could collide with the punch body.

The milled recesses are a deliberate modification that allow the already-bent flange to move into a space where, in a standard punch, the solid body would normally cause interference.

Sheet metal component formed on a press brake, clamped between upper and lower tooling. The image shows a precision bending operation with a complex, multi-bend profile.

Example of a Part Bent Using Horn-Type Punches

When Do We Use This Type of Punch?

Horn punches are essential for bending products such as boxes and covers.

Let’s take a closer look at why.

A “box” is a workpiece that requires segmented tooling—a punch (and sometimes a die) divided into individual sections. At Otinus, we meet this requirement by equipping our press brakes with sectional tools.

Why is this necessary?

When bending all four sides of a closed part, you cannot use a tool of arbitrary length. With a standard full-length punch, previously bent flanges would collide with the tool during subsequent bends.

As bending progresses, the flange from the earlier bend will hit the punch unless the punch length matches the bending length exactly—ideally 5 mm shorter than the flange. Shorter than that, however, and you risk deformation due to unsupported areas.

Cross-section of a bent sheet metal profile, highlighting the bottom flange and side bends in red. The diagram illustrates the final geometry achieved during a press brake bending process.

Profile View of a Workpiece Bent Using Horn Punches

In many cases involving closed boxes, even sectional tools are not enough. Due to bent tabs, reinforcements, or stiffeners, an additional tool with cutouts (horns) is required.

Application of Horn Punches

Horn punches are used whenever the upper flange of the box would cause a collision with the normal punch geometry.
They are often the only feasible method to both perform the bend and remove the finished part from the work area afterward.

You can find such horn punches, for example, from the Polish tooling manufacturer Plasmet.

Larger boxes, or those with long flanges, may require custom-designed horns, especially when the box must be bent at an angle other than 90°.

Two Key Questions Before Bending a Box

  1. In what sequence should the bends be made?
    (Using sectional tools + horn punches for the final internal bends.)

  2. How will you remove the finished part from the work area?
    After the last bend, you may be unable to remove the part in the same orientation as you inserted it.
    Often, the workpiece must be lifted out diagonally, and sometimes the horns must be removed entirely to extract the final shape.

Illustration of press brake tooling showing the punch and die forming a sheet metal profile during a bending operation. The graphic highlights the bending geometry and tool interaction used in precision sheet metal forming.

Example of a Part That Cannot Be Bent Without Horn Punches

Summary

Horn punches with specially milled recesses are used whenever previously formed flanges would collide with the punch profile. They allow you to:

  • bend the component correctly,

  • prevent damage to the workpiece,

  • and safely remove the finished part from the press brake.

Manufacturers continuously develop new tooling solutions to make everyday work easier for operators. In upcoming articles, we’ll discuss more “specialized” tool types used in press brake operations.