This paper describes the simulation and on-line fuzzy logic control of tube bending. By combining elasticity and plasticity theories, a conventional model was developed. The results from simulation were compared with those obtained from testing. The experimental data reveal that there exists certain level of uncertainty and nonlinearity in tube bending, and its variation could be significant. To overcome this, a on-line fuzzy logic controller with self-tuning capabilities was designed. The advantages of this on-line system are (1) its computational requirement is simple in comparison with more algorithmic-based controllers, and (2) the system does not need prior knowledge of material characteristics. The device includes an AC motor, a servo controller, a forming mechanism, a 3D optical sensor, and a microprocessor. This automated bending machine adopts primary and secondary errors between the actual response and desired output to conduct on-line rule reasoning. Results from testing show that the spring back angle can be effectively compensated by the self- tuning fuzzy system in a real-time fashion.