5 Tips for Sheet Metal Design

Sheet metal is an essential material found in a wide range of everyday items—from cars and airplanes to building roofs and even equestrian equipment. This widespread use highlights how crucial sheet metal has become in modern manufacturing. The performance and durability of the final product depend heavily on the quality of the sheet metal used. Therefore, it's vital for sheet metal designers to follow best practices that ensure precision and reliability in their designs. Here are five key tips that can help you create more efficient and effective sheet metal parts.

5 Essential Sheet Metal Design Tips

These design strategies are based on industry-standard manufacturing principles and have been proven to enhance both functionality and cost-effectiveness.

1. Bending Radius: When bending sheet metal, it’s important to consider the minimum bend radius—the smallest radius a material can be bent without cracking or deforming. This value depends on the material type and the forming process. For example, ductile materials like aluminum can handle tighter bends, while mild steel typically requires a minimum radius equal to its thickness. Modern DFM (Design for Manufacturability) tools can help calculate and suggest appropriate radii, ensuring your design is both practical and efficient.

2. Hole Sizes: Accurate hole placement and sizing are critical in sheet metal design. Holes should generally be at least as large as the sheet thickness to avoid issues during punching. If holes are too small, the punch tool may break or cause distortion. Additionally, the space between two holes should be at least twice the material thickness to prevent deformation during forming or bending operations.

3. Flange Width: Flanges are used to reinforce edges or provide structural support. A common rule of thumb is that flange width should be no less than four times the sheet thickness. This helps prevent marking or damage to the material during fabrication and ensures a stronger, more stable structure.

4. Edge Bending: Proper edge bending is essential to improve strength and safety. Avoid sharp 90-degree bends unless necessary, as they can lead to stress concentrations. Instead, opt for angles less than 90 degrees where possible to reduce the risk of cracks or failures.

5. Clearance Between Bend and Hole: To prevent distortion during forming, maintain a safe distance between any hole and the bend line. A general guideline is to keep this clearance at least twice the sheet thickness. This simple adjustment can significantly improve the integrity of the finished part.

By incorporating these design tips into your workflow, you can greatly improve the efficiency, accuracy, and manufacturability of your sheet metal projects. With the right software and attention to detail, you can reduce waste, save time, and produce high-quality components that meet industry standards. Whether you're a seasoned engineer or a new designer, these guidelines are invaluable in creating reliable and cost-effective sheet metal solutions.