5 Tips for Sheet Metal Design

Sheet metal is a fundamental material in modern manufacturing, found in everything from vehicles and aircraft to building structures and equestrian equipment. Its versatility and strength have made it an essential component across various industries. The quality of the final product heavily relies on the precision and care taken during the sheet metal design phase. Therefore, designers must adopt specific strategies to ensure that their designs are not only functional but also cost-effective and easy to manufacture. Here are five essential tips for effective sheet metal design.

5 Essential Sheet Metal Design Tips

These tips are derived from industry-standard practices and are designed to help engineers and designers create high-quality, manufacturable parts with minimal waste.

1. Consider the Bending Radius: When bending sheet metal, the radius of the bend plays a critical role in preventing cracks or fractures. The minimum bend radius is the smallest radius a material can be bent without causing damage. This value depends on the type of material and the forming process used. For example, ductile materials like aluminum can handle tighter bends compared to harder metals like mild steel. In general, the minimum bend radius for mild steel should be at least equal to the material thickness. Modern DFM (Design for Manufacturability) software tools can help determine the optimal bend radius based on material properties and tooling options.

2. Optimize Hole Sizes and Spacing: Holes in sheet metal components need careful planning. It's advisable to make holes slightly larger than the material thickness to avoid issues during punching. If holes are too small, the punches may break or cause distortion. Additionally, maintaining a minimum distance of at least twice the material thickness between holes helps prevent deformation during forming operations. Proper spacing ensures structural integrity and reduces the risk of tearing or warping.

3. Pay Attention to Flange Width: Flanges are used to reinforce edges or provide mounting points. A common rule of thumb is that flange width should be at least four times the material thickness. A narrower flange can lead to marking or even failure under stress. By following this guideline, you ensure both functionality and durability in your design.

4. Plan for Edge Bending: Edge bending is often used to strengthen the edges of sheet metal parts. However, improper bending can lead to complications such as cracking or uneven surfaces. To avoid these issues, it's best to design with angles less than 90 degrees where possible. This allows for better control during the forming process and results in a more reliable final product.

5. Maintain Clearance Between Bends and Holes: One of the most overlooked aspects of sheet metal design is the clearance between a bend and a hole. If the distance between the bend line and the edge of a hole is too small, the hole may deform during the bending process. To prevent this, the recommended clearance is at least two times the material thickness. This simple adjustment can significantly improve the quality and reliability of the finished part.

By incorporating these design strategies, engineers can create more efficient, cost-effective, and high-quality sheet metal components. Pairing these principles with advanced DFM and CAD software ensures that designs are not only creative but also practical for real-world manufacturing. Whether you're designing for automotive, aerospace, or industrial applications, attention to detail in sheet metal design can make all the difference.