To create a 45-degree bend in a cable tray, the cut-out size is calculated by dividing the tray width by 2, based on halving the bend angle.

Step-by-Step Calculation

1. Determine the tray width (A): Measure the width of the cable tray you want to bend. For example, 100 mm.
2. Identify the bend angle (B): For a 45-degree bend, take half of the angle: 45° ÷ 2 = 22.5° .
3. Calculate the cut-out size (D): Use the formula: $$D=\frac{\text{Tray Width (A)}}{90°/\text{Half Angle (B/2)}}$$ For a 100 mm tray and 45° bend:
   • Half angle = 22.5°
   • 90 ÷ 22.5 = 4
   • Cut-out size = 100 ÷ 4 = 25 mm on each side .
4. Mark and cut the tray: Draw the cut lines along the tray edges according to the calculated size. File or remove the lip as needed to allow the bend to overlap smoothly.
5. Bend the tray: Fold the tray so the cuts overlap, forming the 45-degree angle. It is recommended to test with cardboard first to ensure accuracy .

Practical Tips

• For larger bends or multiple angles, divide the total bend into smaller segments (e.g., two 45° bends for a 90° turn).
• When creating offsets around obstacles, calculate the required set using the tray width and offset distance: divide the straight-line distance by the tray width, then divide the offset by this factor to determine the cut size .
• Always consider the physical tray depth, flange overlap, and cable bend radius to avoid crowding or damaging cables . By following this method, you can accurately create 45-degree bends in cable trays of any width and adapt the formula for other angles as needed.