Just wondering if anyone with a metal folder has come across this sort of stress on the outside of a bend, and what might cause it, is my bend too sharp or possibly wrong grade of metal ? I don't think the strength of the metal has been altered too much - though I do think that if I was to bend it back the other way the metal would probably crack along the fold line.

The metal is 2mm aluminium, unknown grade - folded in a home brew folder based largely on Simso's design, the width of the bend is 440mm and this is probably approaching the width limit for bending 2mm aluminium sheet as I detected a slight bow of a mm or so in the bend. I was surprised at the amount of effort needed for the bends - I initially thought my folder was not up to the task, but eventually found all I needed was to put some extra muscle into it.

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