The Ultimate Guide to Press Brake Safety Devices and Guidelines for 2025

ByFrancis Pan

Francis Pan

Introduction

Press brake machines can accurately and efficiently bend a wide variety of sheet metal, widely used in daily processing and high-end manufacturing industries such as automobiles and aviation, and have an important position in sheet metal processing.

While it brings benefits, it also brings certain risks. Every year, there are countless accidents caused by improper operation of press brakes, including machine crushing injuries, high-intensity pinching injuries and amputations.

The safe use of press brakes can not only ensure the safety of every press brake operator’s life, but also bring economic benefits to the enterprise. This article will focus on allowing readers to understand and implement the press brake safety guidelines to reduce the risk of accidents.

Common types of safety accidents in press brakes

Operator’s hand injury

The gap between the press brake tools is very small, and if the press brake operator does not put his hand in the safe zone, he is very likely to be pinched at the moment when the upper and lower tools are closed, resulting in amputation or serious fracture.

Impact caused by plate rebound or slippage

During the bending process, the material may not be fully bent due to its own hard material, which will cause deformation and rebound to the press brake operator. When the brake press has local uneven stress distribution or loose parts, it may cause the plate to slip and hit the operator.

Misoperation of back gauge leads to pinching and dangerous movement

Press brake back gauge is an accessory used to position and support the plate, and when it is positioned or adjusted, it may pinch the operator’s hand that is not in time to be placed in a safe area when retracting forward. In addition, if placed in the wrong place, it can also cause the equipment to move unexpectedly, further increasing the risk.

Injuries caused by unauthorized starting of the machine

During the maintenance or adjustment stage of the machine, it is easy to activate the foot switch or two-handed start switch without authorization because no one reminds it. Then the maintenance personnel who are troubleshooting the fault or have been repaired may be injured by the sudden start of the press brake.

Mechanical failure

When the press brake machine suddenly has mechanical failures such as hydraulic system oil pipe leakage and valve failure during use, resulting in leakage of electricity or tool falling off in the electrical system, it will directly threaten the safety of the operator in a very short time.

Workpiece material ejection or splashing

The plate will be stressed and split into many pieces during cutting or bending. If you’re not careful, these flying debris can bounce off the human body at high speed, stabbing the operator.

Noise and hearing loss

The noise generated by the brake press during operation may reach 85 decibels or even higher, if you do not wear protective equipment such as earplugs or are too close to the equipment, it will cause temporary or even permanent deafness to the press brake operator’s hearing.

Footswitch and footpeg accidents

If an unsecured footswitch or footpeg is accidentally triggered without warning, anyone near the operating point is at direct risk.

Unguarded operation point passage

There will be a phenomenon of non-operators entering and exiting the unsupervised office in the operation area, and if there is no warning sign, visitors or irrelevant personnel will enter the processing area without knowing it, resulting in accidents.

Messy work area

The messy working environment such as oil stains on the ground or tools scattered all over the ground will inevitably increase the risk of tripping, falling and other accidents when uninformed people pass by.

Operate press brake
Operate press brake

Press brake safety operation guide (core part)

Inspection before operation

  • Safe working space: If the work area is full of oil stains, debris and other debris or wires are spread all over the floor, it will lead to slips, trips and other incidents for operators, and sometimes even serious accidents such as accidentally stepping on the footswitch. Regularly cleaning up debris and warning and managing foot switches are necessary preparations for a safe environment.
  • Check whether the emergency stop button and control system are normal: When the entire equipment is out of human control, the emergency stop button is the most important means of saving life. It is necessary to test whether the emergency stop button can be turned on normally before starting the machine.
  • Ensure that the tool is firmly installed: The tool falling off during processing is also a common casualty accident, before and after each use of the press brake, the press brake operator should check the firmness of the tool, and if necessary, use anti-loosening gaskets and other means to increase the fixing stability.
  • Check whether the photoelectric protection device (light curtain) or safety door function is turned on: The function of the light curtain or safety door is to quickly cut off the power supply when an abnormal object enters the processing equipment and avoid machine failure caused by the entry of unknown objects. During daily production, the press brake operator should check whether the light curtain has been removed or obstructed to avoid malfunction.
  • Check whether the hydraulic system is leaking oil or abnormal pressure: Oil leakage or abnormal pressure in the hydraulic system will cause abnormal failures of the machine, and the common practice is to check whether the oil is leaking before use, and install a pressure sensor to automatically detect pressure changes.
  • Confirm that all press brake operators are wearing protective equipment (PPE): Protective equipment such as cut-resistant gloves, safety helmets, and goggles must be worn by every production personnel, and in case of accidents, these safety equipment can sometimes reduce the possibility of casualties.

Safety steps in operation

  • Keep hands away from the tool: When adjusting the tool or moving materials, it is best for press brake operators to use special tools such as pushers, and they should also be careful to stay away from dangerous areas when using them.
  • Use press brake safety light curtains or laser safety protection systems: Installing press brake safety light curtains and other systems can maximize the characteristics of short laser response time and high detection accuracy. Any abnormal object entering the processing area of the equipment can immediately stop the bending to ensure the safety of personnel.
  • Restrict unauthorized operators from entering the operation area: In the operation area, it is necessary to use fences for isolation and post warning signs. In addition, an authorization system can be established to allow only employees to enter and avoid non-operators entering and leaving the work area without permission.
  • Control the risk of plate rebound: If the operator hastily grasps or adjusts the plate before the force is over, the material will rebound. Employees should understand the support and placement techniques of the plates to reduce the risk of rebound.
  • Safe cooperation with the back gauge: When artificially adjusting the press brake back gauge, pay attention to the state of the back gauge, if it is a moving back gauge, do not touch it directly with your hands, and reduce the speed if necessary to avoid hurting the arm.

Cleaning and maintenance after operation

After the operation, the equipment is powered off, and professional cleaning tools are used to clean the residue and oil stains, and after treatment, then check whether the light curtain system is blocked and whether the hydraulic oil is leaking, and finally do a good job in lubrication measures for mechanical equipment.

Common safety protection equipment and technologies

Infrared light curtain protection

The infrared light curtain is composed of a transmitter and a receiver, any object larger than the security system allows the smallest size to pass through the light curtain will be immediately captured, and then the light curtain will immediately trigger the emergency stop mechanism. Infrared light curtains not only have fast response and small errors, but also have high reliability, which is very secure for the safety of press brake operators

Laser protection system

Type of light curtain, press brake safety laser protection system monitors dangerous areas by scanning laser beams, has higher sensing ability than light curtains, and uses more diverse places.

Safety control system

Safety PLC and other safety control systems uniformly manage various signals such as emergency stops, press brake safety light curtains, controllers, pedals, etc., and will generally summarize monitoring data for the processing of key safety signals.

Two-Hand Controls

Two-hand controls are designed so that the press brake operator must press two control buttons simultaneously to activate. Then when the operator adjusts the workpiece, there is no need to worry about the bending machine inadvertently starting and hurting himself, greatly reducing the chance of injury.

Protective cover and safety door

The protective cover made of strong metal mesh or plastic guard net and the safety door using inductive or mechanical safety interlock switches are the most effective means of physical isolation of dangerous areas, and play a good role in restricting the accidental entry of outsiders during operation.

Press brake tonnage safety regulations

The press brake tonnage must be determined according to the thickness of the metal plate and the shape and size of the bending. If too large tonnage is used, it will not only cause damage to the workpiece and machine, but also threaten the personal safety of the operator.

Safety System
Safety System

Common safety mistakes and how to avoid them

Common mistakes are listed

  • Bypassing press brake safety devices: In order to improve efficiency, some press brake operators who do not obey the safety guidelines will artificially close the light curtain, remove the safety door, and cover the emergency stop button during processing. These operations will not only not speed up too quickly, but will also have serious safety hazards. Once an operational error or equipment failure occurs, it is very easy to cause finger amputation accidents.
  • No use of personal protective equipment (PPE): Press brake operators sometimes find it troublesome to choose not to wear cut-resistant gloves, safety shoes, or goggles. Such a fluke mentality is very easy to cause physical injury caused by material rebound or slipping.
  • Distraction: The press brake operator’s attention will gradually decrease with time and environmental pressure, but a small fraction often leads to serious accidents.

Recommendations and best practices to avoid these mistakes

First of all, mandatory press brake safety training should be carried out for every operator to ensure that each operator can use press brake safety devices in a standardized manner. Secondly, the company should formulate safety regulations to greatly punish violations of the regulations. In daily life, be sure to do regular safety inspections, including cleaning machines, cleaning the working environment, and inspecting equipment.

The importance of press brake operator training

Why operational training is more critical than equipment

For a factory, the technical skills of press brake machines are crucial to production, but the final operation depends on the press brake operator’s own skills. In other words, enterprises can not have numbered machines, but they must lack high-quality talents. Only systematic press brake safety training of operators can improve production efficiency and bring economic benefits to enterprises.

Recommended press brake safety training content

  • Press brake operation: First of all, let the press brake operator understand the structure, working principle and function of each component. Secondly, you need to be familiar with various processes, including program setting, material placement, and tool replacement. Finally, the operator should be taught to read the drawings and write the program reasonably according to the parameters on the drawings.
  • Use of press brake safety devices: Tell press brake operators the working principle of light curtain, laser protection, PLC interlock, and two-hand start device, and teach them how to trigger emergency stop, power off procedure and quick troubleshooting ideas in case of fault.
  • Fault handling measures: Conduct simulation drills for common fault problems of the equipment, and understand the rapid handling process of faults. In addition, regular assessments of press brake operators are required to help them remember the handling method firmly.
  • Daily inspection: Enhance the awareness of daily maintenance and inspection of press brake operators, improve the inspection system, and implement the inspection work. Let experienced masters teach the experience of daily inspection, and arrange for operators to test by themselves in the early stage.

Certification requirements and the importance of continuing education

When recruiting press brake operators, job seekers must hold an international third-party safety operator certificate such as ANSI/ASME and must have professional skills to pass the minimum recruitment standards. After being recruited into the company, the interns had to pass the press brake safety training test. After formal work, the formula must also carry out regular continuous education and training to improve the level of the press brake operator.

Press Brake Operator

Regular maintenance and safety review system

Importance of regular maintenance

Reasonable maintenance plays a great role in ensuring the long-lasting and stable operation of equipment. When a good machine appears in assembly line production, it is not only a disguised improvement in production accuracy and efficiency but also a safe medicine to reduce risks and protect safety.

Key maintenance points

  • Hydraulic system: First, pay attention to whether there are problems such as poor oil quality and hydraulic oil leakage, and on this basis, change the hydraulic oil regularly. Secondly, check whether the pressure is stable or unstable during operation, and if it is unstable, it is necessary to stop production, and ask a special master to adjust the calibration.
  • Electrical system: The first aspect mainly checks the switch of the circuit, whether the wires are connected normally, and is wary of circuit faults caused by cable wear. on the other hand, it is necessary to pay attention to whether the operation of the sensor is malfunctioning to ensure that the functions are used normally.
  • Mechanical structure: On the one hand, it is necessary to check whether the relevant moving parts are seriously worn and replace them if necessary. On the other hand, key components such as shafts, lead screws, and back gauge that determine the accuracy of the product must also be lubricated regularly.

Daily, weekly, and monthly checklists

  • Daily：First, check whether safety protection tools such as press brake safety light curtains and protective doors can operate normally and meet effective protection standards. Secondly, clean the surrounding area of debris and redundant tools to eliminate the interference of these debris in the working environment. Finally, check whether the running parts are jammed, apply lubricating oil, and actively repair if there is wear.
  • Weekly：Focus on checking the quality and level of hydraulic oil inside the press brake, and replace the oil with obvious deterioration in quality. If the liquid level is too low to meet the production demand, it is necessary to replenish the oil in time.
  • Monthly：Inspect each part in detail to make sure that all parts are in a tight state and not loose. Simulate production, and fully test the entire body of the equipment to ensure that there are no abnormalities in operation.

It is recommended to create a maintenance log

The maintenance log should record the basic information of all daily maintenance and inspection activities such as maintenance time, location, content, and person in charge, so as to facilitate future access to equipment failure and maintenance records.

There is also a part to accurately record whether the equipment can operate normally after repair, and what parts have been replaced, and take photos for retention. If the maintenance is not good for a while, if there is a decrease in production or a major accident during operation due to unfavorable maintenance, it is convenient to communicate and negotiate with the maintenance party.

Improve security through third-party or internal audits

  • Internal: Conduct internal audit by comparing the implementation rules of CE, ISO, OSHA standards, once every six months, and the specific audit content is the production practice of press brake operators, employee safety awareness testing, etc.
  • Third party: Introduce a more authoritative third-party review or directly invite the original manufacturer to conduct a review, focus on improving the unqualified areas to ensure that the standard guidelines for machine operation are met. At the same time, press brake operators should take safety measures to prevent such risk factors from occurring again.

Related technical reading : Ultimate Guide to Hydraulic Press Brake Maintenance: Top Tools, Schedules & Expert Tips

Comply with relevant standards and press brake safety regulations (applicable to European and American markets)

OSHA (American Occupational Safety and Health Administration) rules

OSHA’s design is mainly to oversee the safe operation of press brakes in the United States, which clearly stipulates that press brake operators must wear PPE and other daily press brake safety measures to ensure the normal operation of all press brake safety devices, and set up security measures such as prompts and light curtain protection in dangerous areas.

ANSI B11.3 Rules

In OSHA standards, ANSI B11.3 also provides detailed regulations on how to use protective devices such as press brake safety light curtains, presence sensing devices, and two-hand drive systems. In addition to these, there is strong support for new technologies such as active optoelectronic protection devices, emphasizing the need for safe distance calculation and control circuit verification.

Global safety standard for press brakes (ISO 13849-1)

ISO 13849-1 specifies the level of risk encountered by press brakes according to three aspects: severity, frequency and casualty rate. It aims to warn press brake operators of the risk factor in the operation process according to the level to prevent it in advance.

CE certification and the EU Machinery Directive (EN 12622)

CE certification is highly demanding, and press brake manufacturers generally need to meet international standards for protective equipment, electrical systems and control circuits, which greatly reduces the risk of user purchase and increases safety and reliability. EN 12622 sets out mandatory requirements for security facilities such as press brake protective devices and light curtain performance, providing a basis and standard for the European region.

What are the legal and financial consequences of neglecting press brake safety?

Fines and penalties from regulatory agencies

If there is a major accident due to insufficient safety performance of safety facilities, the regulatory agency will personally enter the enterprise to conduct interviews and take staff to conduct professional tests to see if it is true. Once the inspection results show that the safety performance is below the national minimum standard, the regulator will fine the company in accordance with the law, sometimes up to millions of dollars.

Legal liability for work-related injuries

If the staff strictly abides by the press brake safety regulations at work, but is injured due to the safety of the brake press itself, it will be judged as a work-related injury, and the company shall bear medical responsibility and compensation for the employee’s work-related injury. If it is found to be negligent management, it will be criminally liable.

Financial impact of machine downtime due to safety negligence

  • Short-term: During the shutdown of the press brake, the corresponding production order cannot be advanced, resulting in the delay in order delivery, and liquidated damages may be required according to the contract. If you want to repair again, you need to pay high maintenance parts fees and hourly fees for repairers. During this period, although press brake operators and other related personnel could not work during the shutdown, they still needed to be paid by the enterprise.
  • Long-term: Unstable production due to safety issues will increase employee turnover, recruitment costs may rise, and reduce customer trust in the company’s ability to perform contracts.

Conclusion

As a high-precision metal forming equipment, press brake machines will definitely be accompanied by high risks, so compliance with safe operation guidelines is the basis for ensuring the life of equipment and stable production, and it is also the foundation for ensuring the safety of employees.

In order to facilitate the practical application and implementation of safety operations for users in the enterprise, we provide readers with a download link to the safety checklist, which contains the safety inspection items of the whole process of press brakes and the precautions for daily maintenance.

If you still have questions, please consult or contact our link, we will dispatch a professional technical team to answer your questions about press brake safety online.

Frequently Asked Questions (FAQs)

The first thing is not to take away protective tools at will during processing for ease of operation, and to ensure that you wear a full set of PPE. Follow strict inspection procedures before production and processing to confirm that all press brake safety devices are effective; Always be aware of potential hazards and avoid getting your hands close to the tool. Clean up and maintain the equipment in time after operation.

Typical injuries include mechanical pinching, material splash puncture, plate rebound injury, electrical loss injury, noise-induced hearing loss, back gauge movement pinching, etc.

There are protective doors,press brake safety laser safety monitoring, and infrared light curtains that use physical methods to isolate dangerous areas, as well as control press brake safety devices that use emergency stops, such as two-handed operation buttons, emergency stop buttons, etc.

There are three main points: the first point, the brake press should provide a variety of safety protection methods to protect operators and other employees, and the protective device should ensure that there will be no accidental danger when the machine is running; The second point is that the electrical system of the press brake must pass the national inspection, comply with safety specifications, and prevent electrical accidents. Finally, during the maintenance of the press brake, be sure to lock or tag it, and isolate the power supply to ensure that there is no interference from idle personnel during maintenance.

First, check the safety equipment and the condition of the processing equipment before machining. Secondly, adjust the press brake back gauge and start the safety device. And then wear protective tools such as PPE all over the body, and then activate the two-handed activation device for processing. Finally, check whether the product is qualified and finally check and repair after delivery.

The specific process is to turn off the power in the first step, the second step is to hang a safety tag with the operator’s signature at the control cabinet and power supply, and the third step is to check and confirm by the maintenance personnel one by one.

First of all, it is strictly forbidden to take off the armor during processing. Secondly, ensure that you stay awake before operation to prevent accidents caused by fatigue or drunk work. In addition, it is also necessary to post warning signs and increase early warning devices, and it is strictly forbidden for non-professionals to enter and exit during operation.

Before and after use, let professionals conduct hierarchical inspections, focusing on checking hydraulic oil, electronic control equipment and various parts of the mechanical structure, stop operation immediately if problems are found, and strictly record the problem parts for subsequent maintenance.

Operators need to pass technical and safety knowledge training, inspection equipment and safety device operation training, and fault handling training.

When using a press brake machine, avoid not wearing protective equipment for ease of operation, distracting operations such as fatigue or alcohol or looking at mobile phones, bypassing the activation of press brake safety devices depending on the length of processing time, etc.

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Francis Pan

Francis Pan

Francis Pan is the Foreign Trade Manager of RAYMAX, with over 10 years of experience in sheet metal fabrication equipment and CNC machinery. He has worked closely with manufacturers worldwide on press brakes, fiber laser cutting machines, fiber laser welding machines, and practical production-oriented metal processing solutions.

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