5 Tips for Sheet Metal Design

Sheet metal is a fundamental material used in countless everyday products, from vehicles and aircraft to building roofs and equestrian equipment. This widespread use highlights the essential role sheet metal plays in modern manufacturing. The quality of the sheet metal directly impacts the reliability and performance of the final product. As a result, sheet metal designers must adopt effective design strategies to ensure precision and efficiency in production. Below are five key tips that can help improve your sheet metal design process.

5 Essential Sheet Metal Design Tips

The following guidelines are based on industry-standard practices and are designed to optimize both functionality and manufacturability.

1. Bending Radius: When bending sheet metal, it's crucial to consider the minimum bend radius—the smallest radius a material can be bent without cracking. This value depends on the material type, thickness, and forming method. For example, ductile materials can handle tighter bends, while mild steel typically requires a minimum radius equal to its thickness. Modern DFM (Design for Manufacturability) software helps engineers determine optimal radii, ensuring better accuracy and fewer production issues.

2. Hole Size and Spacing: Properly specifying hole size and placement is critical in sheet metal design. Holes should be at least as large as the sheet thickness to avoid distortion or breakage during punching. Additionally, the space between two holes should be at least twice the sheet thickness to prevent deformation during forming or bending operations. Careful planning here can significantly reduce defects and rework.

3. Flange Width: Flanges are structural features that provide strength or aid in assembly. A common rule of thumb is that flange width should not be less than four times the material thickness. This ensures sufficient support and prevents damage or marking on the surface during fabrication.

4. Edge Bending: Edge bending is often used to reinforce the edges of sheet metal parts. However, improper bending angles can lead to warping or cracks. It’s advisable to design with angles smaller than 90 degrees when possible, as they are easier to form and less likely to cause complications during the manufacturing process.

5. Clearance Between Bend and Hole: Maintaining proper clearance between a bend and a hole is essential to prevent deformation. The general rule is that the distance from the bend line to the edge of the hole should be at least twice the material thickness. This helps maintain the integrity of the part during subsequent forming operations.

By following these design principles and utilizing advanced DFM tools, you can create more efficient, cost-effective, and high-quality sheet metal components. Thoughtful design not only improves the final product but also reduces waste and enhances overall production efficiency. Whether you're designing for mass production or custom applications, these tips can make a real difference in your workflow.