5 Tips for Sheet Metal Design

Sheet metal is a fundamental material used in a wide range of everyday products—from cars and airplanes to building roofs and even equestrian equipment. This versatility makes it an essential component in modern manufacturing. The quality of the sheet metal directly impacts the reliability and durability of the final product. As a result, sheet metal designers must follow specific design strategies to ensure precision and efficiency during the manufacturing process. Let’s explore some key tips that can help you create better sheet metal designs.

5 Essential Sheet Metal Design Tips

These design strategies are based on industry best practices and are widely adopted in the manufacturing sector. Implementing them can significantly improve the performance and cost-effectiveness of your sheet metal projects.

1. Bending Radius: When bending sheet metal, it's crucial to consider the minimum bend radius. This refers to the smallest radius a metal can be bent without cracking or deforming. The minimum bend radius depends on the type of metal and the manufacturing process. For example, ductile materials like aluminum allow for smaller radii, while mild steel typically requires a radius equal to its thickness. Using DFM (Design for Manufacturability) software can help ensure accurate calculations and prevent costly errors.

2. Hole Sizes: Properly specifying hole size and placement is vital in sheet metal design. It’s advisable to make holes larger than the sheet thickness to avoid using excessively small punches, which can cause distortion or breakage. Additionally, maintain at least twice the sheet thickness between adjacent holes to prevent deformation during forming or bending operations.

3. Flange Width: Flanges are used to reinforce edges or provide structural support. A general rule is that the flange width should not be less than four times the sheet thickness. A narrower flange may lead to marks or weak points, reducing the overall integrity of the part.

4. Edge Bending: Edge bending enhances strength and safety, especially in applications where sharp edges could be hazardous. However, improper bending can cause issues. To avoid complications, it's recommended to use angles less than 90 degrees when possible, as they are easier to form and reduce stress on the material.

5. Clearance Between Bend and Hole: Maintaining proper clearance between a bend and a hole is essential to prevent deformation during other manufacturing steps. The distance between the bend line and the edge of the hole should be at least twice the thickness of the metal. This ensures the part remains intact and functional after all processes are completed.

By following these design tips and utilizing advanced DFM tools, you can create more efficient, cost-effective, and high-quality sheet metal parts. Good design not only reduces waste but also streamlines production, making it an essential part of any successful manufacturing project. Whether you're working on industrial components or custom solutions, attention to detail in sheet metal design can make a world of difference.