Structural engineer and ride maker Maurer has launched XBEND, enabling high-precision computerised manufacture of coaster track tubes.

The computer-controlled machine can be programmed to create complex bends in large tube diameters with the highest degrees of accuracy. This increases the safety, feel and quality of the ride.
XBEND uses a 3D CNC (computer numerical control) bending procedure, which converts the track design created with CAD software into numbers, plotting them as coordinates in a graph that controls the path of the machine that cuts and shapes the tubes.

“XBEND is an important component for us on the path towards integrated rollercoaster manufacturing, where we have linked up various modules with each other,” said CEO Jörg Beutler, referring to Maurer’s in-house simulation program and software package.
Previously Maurer has manufactured the track tubes by hand using roller bending machines, a task that requires huge skill to achieve a smooth finish with no irregularities on often complex track designs.

“Our existing bending machines, which were designed by roller coaster pioneer Anton Schwarzkopf, are operated by veteran staff – some with over 20 years experience,” said Martin Schneider, head of technology and automation at Maurer. “Despite this, remedial work with the use of flame straightening could never quite be avoided during track production to achieve the required geometric tolerances.”
The XBEND machine delivers levels of precision that were not possible by hand, creating “continuous curvature progression and torsion along [the tubes] entire length as well as a high level of geometric accuracy,” he said.

Maurer has already used XBEND in the manufacture of a spinning coaster at Shaoxing Amusement Park, China, and the upcoming Sky Dragster “motorbike coaster” at Allgäu Skyline Park in Germany.