Designing for sheet metal fabrication involves more than just sketching a functional shape. By applying certain principles early in the design phase, engineers and product designers can improve manufacturability, reduce costs, and streamline production. Below are some key considerations to keep in mind when working with this versatile material.
Keep Bends Simple and Consistent
Bending is one of the most common operations in sheet metal fabrication, but it can quickly become costly or inaccurate if the design includes overly complex geometries. In general, the thicker the material, the higher the bend radius must be. This not only avoids cracking or warping but also ensures consistent results across production batches.
Designers are also advised to maintain a uniform bend direction throughout a part where possible. Consistency reduces the need for reorientation during manufacturing, saving time and labour. Incorporating standard bend radii and angles aligned with tooling capabilities further simplifies production and helps maintain tight tolerances.
Choose Appropriate Materials and Tolerances
Selecting the right material is essential for both functionality and cost-efficiency. While stainless steel and aluminium are popular choices, material thickness plays a key role in performance and formability. Designers should aim to use standard gauges and avoid unnecessary thickness, which can introduce complications in bending or require specialised tooling.
Equally important is how tolerances are applied. Over-specifying tolerances on non-critical features can drive up costs without improving part quality. Instead, tolerances should be prioritised for areas that influence assembly or mechanical performance. A considered approach in this area leads to more economical and efficient outcomes.
For more in-depth insights into how material type and thickness impact fabrication processes, The Engineer provides useful guidance in its recent article.
If you are looking for more support, a sheet metal fabrication specialist such as //dkmsheetmetal.co.uk offers a range of services for designers seeking sheet metal solutions, and staying aware of fabrication constraints ensures that projects move smoothly from concept to completion.
Ultimately, well-informed design choices help optimise both the quality and cost of sheet metal products, making early-stage planning crucial in any successful project.
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