BR100 Powered Bead Roller

Designed for professional forming of beads, grooves, stiffening ribs, and details in sheet metal, the BR100 Powered Bead Roller combines an extensive working depth, high torque, and precise control for the fabrication and restoration of automotive panels.

Its 1,030 mm throat depth makes it possible to reach deep into the workpiece and handle large panels. With the adjustable shaft extension, available as an optional accessory, the working depth can be increased to approximately 1,100 mm.

This capacity makes the BR100 especially suitable for classic car restoration shops, hot rod builders, coachbuilding, automotive customization, and professional metal shaping applications.

High Torque at Low Speeds

One of the BR100’s key advantages is its high torque capacity, developed to provide consistent forming force even at extremely low operating speeds.

This feature allows beads to be formed progressively and under control, maintaining smooth and stable movement as the sheet metal passes between the dies.

Its substantial torque reserve also provides greater confidence during demanding operations by reducing power loss, speed fluctuations, and interruptions that could affect the accuracy of the work.

The result is a powerful, smooth, and predictable machine that gives the operator greater control when working with different materials, thicknesses, and forming profiles.

Backstage Torque Drive System

The BR100 incorporates the exclusive Backstage Torque Drive, a proprietary drive and control system developed specifically for sheet metal forming operations.

Rather than simply rotating the dies, the system manages the machine’s force delivery and operating speed to provide progressive, stable, and precise response throughout the forming process.

Its main benefits include:

• High torque available from extremely low speeds;

• Progressive and controlled power delivery;

• Smooth operation without sudden movements;

• Precise control of the forming speed;

• Predictable response to operator commands;

• Reversible direction of rotation;

• Greater control over sheet metal feed;

• Improved stability during continuous operation;

• Greater precision when producing straight, curved, or circular beads.

The Backstage Torque Drive allows the operator to work slowly whenever precision is the priority, without sacrificing the force required to form the sheet metal.

This combination helps reduce unwanted distortion, deviations from the intended path, and marks caused by irregular feeding, providing greater control over every stage of panel forming.

Foot-Pedal Operation

The machine is operated by an industrial foot pedal, keeping both of the operator’s hands free to position, support, and guide the panel throughout the entire forming process.

This system provides greater control over the path of the sheet metal, particularly when working with large panels, complex geometries, or operations requiring continuous changes in direction.

Easily Accessible Controls

The main controls are positioned on the front of the machine, within easy reach of the operator, allowing quick adjustments during operation.

The control panel includes:

• Forming speed control;

• Direction-of-rotation selector;

• Start/enable control;

• Machine-powered indicator light;

• Emergency stop/off button.

This arrangement makes it easier to control the machine without compromising the positioning or guidance of the metal panel.

Safety and Component Protection

The emergency stop button is located in an easily accessible position, allowing the machine to be stopped immediately whenever necessary.

The indicator light provides a clear visual signal when the equipment is energized, contributing to safer operation.

The entire drive, transmission, control system, and internal components are enclosed within a steel cabinet.

In addition to preventing contact with moving parts, this protection reduces the entry of debris and contributes to the durability, reliability, and preservation of the machine’s internal systems.

Working Capacity

The BR100 Powered Bead Roller is designed to work with:

• Aluminum up to 1.5 mm thick;

• Cold-rolled low-carbon steel up to 1.2 mm thick;

• Stainless steel up to 0.9 mm thick.

Included Items

The BR100 includes:

• A set of five die pairs, totaling ten rolls;

• Pedestal with floor-mounting base plates;

• Toolkit with wrenches for machine adjustment and maintenance.

Optional Accessories

The BR100 can be configured with different accessories according to the requirements of each workshop:

• Additional dies, with more than 30 profiles available;

• Support table for large panels with an integrated compass-style system for circular beads;

• Adjustable fence for producing straight or radiused beads;

• Adjustable shaft-extension assembly.

Technical Specifications

Model: BR100

Working capacity:

• Aluminum: up to #16 — 1.5 mm;

• Low-carbon steel: up to #18 — 1.2 mm;

• Stainless steel: up to #20 — 0.9 mm.

Throat depth: 1,030 mm
Working depth with shaft extension: up to approximately 1,100 mm

Machine Dimensions

Overall height: 1,370 mm
Width: 500 mm, without optional accessories
Approximate depth: 1,670 mm, without optional accessories
Net weight: 152 kg

Shipping Dimensions

Gross weight: 180 kg
Package length: 1,800 mm
Package width: 600 mm
Package height: 500 mm

Optional accessories: support table, sheet metal fences, additional dies, and adjustable shaft-extension assembly.

Images are for illustrative purposes only. Backstage Tools reserves the right to make technical, structural, or visual modifications to the product without prior notice.