Sheet

Metal
Design
Guide
Introduction to Sheet Metal Design
Modern manufacturing relies heavily on sheet Following material selection, the design is prepared
metal fabrication, as it provides versatility, for fabrication, involving processes such as laser
efficiency, and innovation. From automotive cutting or waterjet cutting to precisely cut sheet
to aerospace, electronics to architecture, the metal into desired shapes and sizes. We’ll dig
applications of sheet metal are vast and further into these steps later on.
diverse, shaping industries worldwide.
Throughout the design process, factors such as
It offers unparalleled flexibility, precision, and bend allowance, tolerance considerations, and
cost-effectiveness for a wide range of components assembly requirements must be carefully
and products. Its versatility allows for the creation considered to ensure manufacturability and
of intricate shapes, complex geometries, and functionality. By leveraging advanced design tools,
custom designs, making it indispensable in the material knowledge, and fabrication techniques,
manufacturing of everything from automotive professionals can create sheet metal components
bodies to medical devices. that meet the highest standards of quality,
performance, and efficiency.
The design process in sheet metal fabrication
encompasses several key stages, each crucial This guide aims to provide a comprehensive
for achieving optimal results. It begins with overview of sheet metal design principles,
conceptualization and design, where designers techniques, and best practices, equipping
leverage CAD (Computer-Aided Design) software designers and engineers with the knowledge and
to create 3D models of parts or assemblies. Next resources necessary to harness the full potential
comes material selection, where considerations of this transformative technology. In the following
such as material type, thickness, and properties sections, we will delve deeper into the intricacies
are evaluated based on functional requirements of sheet metal design, exploring key concepts,
and manufacturing constraints. guidelines, and insights that can empower
organizations to excel in their sheet metal
fabrication endeavors.

Sheet Metal Design Guide 2

What’s Inside

01 Sheet Metal Materials pg. 4

02 Basic Principles of Sheet Metal Design pg. 8

03 Design Considerations pg. 11

04 Joining Methods pg. 14

05 Designing for Strength and Rigidity pg. 18

06 Designing for Manufacturing Efficiency pg. 22

07 Designing for Assembly pg. 25

08 Cost Considerations pg. 27

Sheet Metal Design Guide 3

 01
Sheet Metal Materials

Sheet Metal Design Guide 4

Common Materials Used in Sheet Metal Fabrication

Steel

Steel is one of the most widely used materials in sheet metal fabrication due to its strength, durability, and
affordability. It comes in various grades and finishes, with options such as carbon steel, stainless steel, and
galvanized steel, each offering specific properties suited to different applications. Carbon steel is commonly used
for structural components, while stainless steel is favored for its corrosion resistance in harsh environments.

Aluminum

Aluminum is championed for its lightweight nature, corrosion resistance, and excellent formability, making
it ideal for applications where weight reduction and aesthetics are priorities. Commonly used alloys include
6061 and 5052 aluminum, which offer a good balance of strength, machinability, and weldability. Aluminum
is widely used in the aerospace, automotive, and consumer electronics industries.

Copper

Copper is valued for its electrical conductivity, thermal conductivity, and corrosion resistance, making it
suitable for electrical and electronic applications. It is often used to make electrical components, heat
exchangers, and architectural features where its distinctive appearance adds aesthetic value.

Brass

Brass is an alloy of copper and zinc, prized for its attractive golden color, corrosion resistance,
and machinability. It is commonly used in decorative applications, plumbing fixtures, and musical
instruments where its aesthetic appeal and durability are desired.

Stainless Steel

Stainless steel offers excellent corrosion resistance, high strength, and durability, making it suitable for a
wide range of applications in harsh environments. It is commonly used in industries such as food processing,
chemical processing, and marine engineering where corrosion resistance is critical.

Titanium

Titanium is valued for its high strength-to-weight ratio, corrosion resistance, and biocompatibility,
making it ideal for aerospace, medical, and automotive applications. It is often used in sheet metal
6
fabrication for components requiring exceptional strength and durability.
Material Properties
Affecting Design

Material properties significantly influence

the design of sheet metal components. By
understanding these material properties and
their effects on design, one can make informed
decisions when selecting materials and optimizing
designs for specific performance requirements
and manufacturing processes.

Strength

Ductility

Corrosion Resistance

Machinability

Weldability

Thermal Conductivity

Electrical Conductivity

Sheet Metal Design Guide 6

Strength Machinability
Material strength refers to a material’s ability Machinability refers to a material's ease of
to withstand applied loads without deformation machining and processing during fabrication.
or failure. High-strength materials, such as Materials with good machinability, such as
high-carbon steel or titanium alloys, are favored low-carbon steel and certain aluminum alloys,
for applications requiring structural integrity and allow for efficient material removal, tool life, and
load-bearing capacity. Designers may specify surface finish quality. Consider machinability when
thicker material gauges or reinforcement features you need materials for parts requiring intricate
to accommodate higher loads and stresses. machining operations or tight tolerances.

Ductility Weldability
Ductility refers to a material's ability to deform Weldability is the ease with which a material can
under tensile stress without fracture. Materials be welded or joined to other materials. Materials
with high ductility, such as aluminum and certain with good weldability, such as mild steel and
steels, are easier to form and shape during stainless steel, make for strong and reliable weld
fabrication processes like bending, stretching, and joints without the risk of defects or brittleness.
deep drawing. Designers can leverage ductility to Always ensure compatibility between materials
create complex geometries and intricate shapes and welding techniques to achieve robust
without the risk of cracking or failure. welded assemblies.

Corrosion Resistance Thermal Conductivity

Corrosion resistance is crucial for materials Thermal conductivity refers to a material's ability
exposed to harsh environments or corrosive to conduct heat. Materials with high thermal
substances. Stainless steel, aluminum, and certain conductivity, such as copper and aluminum, are
alloys are prized for their corrosion resistance, preferred for heat transfer applications, such as
making them suitable for outdoor applications, heat exchangers or electronic cooling systems.
marine environments, and chemical processing Leverage thermal conductivity by optimizing heat
facilities. Corrosion-resistant materials should dissipation and thermal management in sheet
be prioritized for parts exposed to moisture, metal components.
chemicals, or corrosive gasses.
Electrical Conductivity
Electrical conductivity is the ability of a material to
conduct electricity. Materials with high electrical
conductivity, such as copper and aluminum, are
used in electrical and electronic applications where
efficient electrical transmission is essential. When
necessary, select materials with the appropriate
electrical conductivity for parts requiring electrical
conductivity or insulation properties.

Sheet Metal Design Guide 7

 02 Basic Principles of
Sheet Metal Design

Sheet Metal Design Guide 8

Understanding Bend Allowance, Bend Deduction, and K-Factor

Achieving accurate and precise bends is crucial for Bend Deduction: Bend deduction, also known
fabricating components with the desired dimensions as bend compensation or setback, is the amount
and geometries. Key to this process are concepts of material that must be removed from the flat
such as bend allowance, bend deduction, and pattern to account for stretching during bending.
K-factor, which play significant roles in determining It represents the difference in length between the
the dimensions of flat patterns and the accuracy flat pattern and the formed part. By subtracting
of bent parts. the bend deduction from the flat pattern length,
fabricators can accurately determine the length
Understanding bend allowance, bend deduction, of material needed for bending operations.
and K-factor is essential for achieving precise and Bend deduction is particularly important for
accurate bends in sheet metal components. By achieving precise bend angles and dimensions
properly accounting for material stretching and in sheet metal components.
compression during bending operations, designers
and fabricators can produce high-quality parts with K-Factor: The K-factor is a dimensionless
the desired dimensions and geometries, ultimately parameter used to calculate bend allowance and
ensuring the success of their sheet metal bend deduction based on the material thickness,
fabrication projects. bend radius, and bend angle. It represents the
ratio of the distance from the neutral axis of the
Bend Allowance: Bend allowance refers to the bend to the inside surface of the material to the
amount of material that will be stretched or material thickness. The K-factor accounts for
elongated on the outside surface of a bend. When material properties and bending characteristics,
a sheet metal part is bent, the material along the such as spring back and stretching, and varies
inner radius of the bend compresses while the depending on factors such as material type,
material along the outer radius stretches. Bend thickness, and bending method. By accurately
allowance compensates for this stretching by determining the K-factor, designers and fabricators
adding extra material to the flat pattern before can ensure the integrity and accuracy of bent
bending, ensuring that the final bent part achieves parts in sheet metal fabrication.
the desired dimensions. Understanding bend
allowance is essential for accurately calculating
the length of the flat pattern required for
bending operations. Mathematically, the
K-factor represents
the ratio between the
position of the neutral
axis (t) and the plate
thickness (T).

Sheet Metal Design Guide 9

Tolerances and Allowances in Sheet Metal Fabrication

Tolerances and allowances are critical concepts

that govern the dimensional accuracy, fit, and
functionality of fabricated parts. By carefully
considering tolerances and allowances in sheet
metal design and fabrication, designers can ensure
that parts meet their dimensional requirements,
fit properly with mating components, and perform
reliably in their intended applications. Effective
management of tolerances and allowances is
essential for achieving high-quality, cost-effective
sheet metal components.

Tolerances: Tolerances refer to the allowable Allowances: Allowances are intentional deviations
variation in dimensions, specified as permissible from nominal dimensions designed to account for
deviations from the intended or nominal factors such as material properties, manufacturing
dimensions of a part. Tolerances are essential processes, and assembly requirements. Unlike
for ensuring that parts meet design requirements tolerances, which specify permissible deviations,
and functional specifications. They account for allowances are predetermined adjustments
variations in manufacturing processes, material applied during fabrication to ensure proper fit,
properties, and environmental factors that can functionality, and ease of assembly.
affect part dimensions.
Common allowances include bend allowances,
Tolerances are typically specified as a range or limit bend deductions, and clearance allowances. Bend
around a nominal dimension, such as ±0.005 inches allowances compensate for material stretching
or ±0.1 millimeters. Tighter tolerances indicate a during bending operations, ensuring that the final
smaller allowable deviation from the nominal bent part achieves the desired dimensions. Bend
dimension and require higher precision in fabrication deductions account for material compression and
processes. Conversely, looser tolerances allow for are subtracted from the flat pattern length to
greater variation and are suitable for less critical determine the length of material required for
dimensions or less precise applications. bending. Clearance allowances provide additional
space or clearance between mating parts to
Tolerances may be specified for various accommodate assembly tolerances, thermal
dimensions, including length, width, thickness, expansion, or surface finishes.
hole diameter, bend angle, and flatness. Carefully
consider functional requirements, manufacturing
capabilities, and cost constraints when determining
tolerances for sheet metal parts.

Sheet Metal Design Guide 10

 03Design Considerations

Sheet Metal Design Guide 11

Minimum Bend Radius and Bend Relief Hole Placement and Sizes

Minimum bend radius and bend relief are crucial Hole placement and sizes are critical design
design considerations in sheet metal fabrication considerations in sheet metal fabrication, as they
to ensure the structural integrity and dimensional directly impact part functionality, assembly, and
accuracy of bent parts. structural integrity.

The minimum bend radius specifies the smallest Accurate hole placement ensures alignment with
allowable radius for bends in sheet metal, mating components and facilitates assembly,
preventing material cracking or deformation reducing the risk of misalignment or interference
during bending. Be sure to adhere to minimum issues. Properly sized holes accommodate
bend radius guidelines to avoid defects and fasteners, connectors, and other components
maintain part quality. to ensure secure attachment and optimal
performance of the final assembly. Considerations
Bend relief, such as fillets or cutouts, is added to such as hole spacing, edge distances, and
sheet metal designs near bends to reduce stress deburring requirements further contribute
concentrations and minimize the risk of material to part manufacturability, dimensional
failure. Properly designed bend relief features help accuracy, and overall quality.
distribute bending forces evenly, improving part
durability and extending service life.

Thickness of Minimum
the Sheet Bend Radius

1 time the thickness

1-6 mm
of the sheet

2-3 times the thickness

12-25 mm
of the sheet

1.5 times the thickness

6-12 mm
of the sheet

Sheet Metal Design Guide 12

Edge Treatments
and Finishing Options

Edge treatments and finishing options are vital

design considerations in sheet metal fabrication,
as they impact part aesthetics, functionality,
and durability.

Proper edge treatments, such as deburring or

chamfering, remove sharp edges and burrs,
enhancing safety and preventing injury during
handling and assembly. Additionally, edge
treatments improve the appearance of parts
and facilitate smoother surface finishes, which
contribute to better product quality and higher
customer satisfaction. Flat Pattern Development

Finishing options, such as painting, powder

Flat pattern development is a critical design
coating, or plating, not only enhance part
consideration in sheet metal fabrication, acting
aesthetics, but also protect against corrosion,
as the blueprint for manufacturing bent parts.
wear, and environmental degradation. By selecting
appropriate finishing options, you can ensure that
Accurately developing the flat pattern ensures that
sheet metal parts meet aesthetic requirements,
the dimensions, features, and bend allowances are
functional specifications, and performance
correctly represented, enabling precise fabrication
standards for your intended applications.
of the final part. Proper flat pattern development
also allows fabricators to optimize material usage,
minimize waste, and achieve cost-effective
production. Considerations such as bend sequence,
nesting efficiency, and tooling requirements are
also taken into account during flat pattern
development to streamline manufacturing
processes and ensure part quality.

Sheet Metal Design Guide 13

 04 Joining Methods

Sheet Metal Design Guide 14

Welding Techniques for Sheet Metal

There are many different welding techniques for sheet metal fabrication. Each one has its own set of
advantages and limitations, and the choice of method depends on factors such as material type, thickness,
geometry, production volume, and desired weld quality. Selecting the appropriate welding technique and
parameters ensures strong, reliable welds in sheet metal components.

Let’s cover some of the most common types of welding techniques to help you get a sense
of which method best fits your needs.

Gas Metal Arc Welding (GMAW or MIG) Projection Welding

GMAW, also known as MIG (Metal Inert Gas) Projection welding is similar to resistance spot
welding, is a widely used welding process for sheet welding, but here, it involves the use of specially
metal fabrication. It uses a consumable electrode designed electrodes to create localized projections
wire fed through a welding gun, along with a or embossments on one of the mating surfaces.
shielding gas (typically argon or a mixture of argon These projections concentrate heat and pressure
and carbon dioxide), to create an arc and melt during welding, resulting in strong, uniform welds.
the base metals. GMAW offers high productivity, Projection welding is commonly used for joining
excellent control over weld bead appearance, sheet metal parts with irregular shapes or
and suitability for thin gauge materials. varying thicknesses.

Gas Tungsten Arc Welding (GTAW or TIG) Seam Welding

GTAW, also known as TIG (Tungsten Inert Gas) Seam welding is a continuous welding process
welding, is another popular welding process for used to create long, continuous welds along the
sheet metal. It uses a non-consumable tungsten length of overlapping sheet metal seams. It
electrode and a shielding gas (usually argon) to involves feeding the sheets between rotating
create an arc and melt the base metals. GTAW electrode wheels, which apply pressure and
provides precise control over heat input, produces generate heat to form a weld seam. Seam welding
clean and high-quality welds, and is suitable for is ideal for producing leak-tight and hermetic seals
welding thin gauge materials and non-ferrous in sheet metal assemblies, such as fuel tanks,
metals like aluminum and stainless steel. ductwork, and pressure vessels.

Resistance Spot Welding

Resistance spot welding is a fast and efficient
welding process commonly used for joining sheet
metal parts in automotive and appliance industries.
It uses electrodes to clamp and apply pressure to
the sheets while passing a high electrical current
through the joint area. The resistance of the
materials generates heat, melting the base metals
and forming a weld nugget. Resistance spot welding
is ideal for high-volume production and offers
strong, consistent welds with minimal distortion. 15
Mechanical Fastening Options

Each mechanical fastening method offers unique advantages and considerations, such as ease of
installation, strength, reliability, and reusability. By selecting the appropriate fastening method based
on their application requirements and design constraints, manufacturers can achieve strong and
reliable joints in sheet metal assemblies.

Screws and Bolts Self-Clinching Fasteners

Screws and bolts are widely used for securing Self-clinching fasteners are specially designed
sheet metal parts together. They typically consist of fasteners that are installed directly into
a threaded shaft with a head on one end and a nut pre-punched holes in sheet metal. They feature
on the other. They provide strong and reliable a serrated shank or knurled body that embeds
connections, making them suitable for a wide into the sheet material when pressed into place,
range of applications. creating a secure and permanent connection.
Self-clinching fasteners eliminate the need for
Rivets additional hardware on the backside of the sheet
Rivets are permanent mechanical fasteners that and are commonly used in applications requiring
consist of a cylindrical shaft with a head on one high-strength threaded connections.
end and a tail on the other. They are installed by
inserting the shaft through pre-drilled holes in the Sheet Metal Clips and Clamps
sheets to be joined and then deforming the tail end Sheet metal clips and clamps are pre-formed
to form a second head, creating a secure and components that provide quick and easy
permanent connection. Rivets offer excellent shear attachment of sheet metal parts. They typically
and tensile strength and are ideal for applications feature spring-like arms or tabs that grip the edges
where vibration or dynamic loads are present. of the sheets, holding them securely in place
without needing additional fasteners. Clips and
Clinching clamps are often used in applications where
Clinching is a cold-forming process used to join frequent disassembly and reassembly are required.
sheet metal components without additional
fasteners. It involves deforming the material Threaded Inserts
around a die or punch to create a mechanical Threaded inserts are metal inserts with internal
interlock between the sheets. Clinched joints offer threads that are installed into pre-drilled holes in
good strength and reliability and are suitable for sheet metal. They provide a durable and reusable
thin-gauge materials and applications where means of creating threaded connections in sheet
welding or fasteners are impractical. metal components. Threaded inserts can be
installed using various methods, including
press-fit, heat-insertion, or self-tapping.

Sheet Metal Design Guide 16

Adhesive Bonding in
Sheet Metal Assemblies

Adhesive bonding is a versatile and effective

method of joining sheet metal components in
a wide range of applications. It involves using
adhesives or bonding agents to create strong
and durable bonds between metal surfaces.

Various types of adhesives are used for bonding

sheet metal, including epoxy adhesives, cyanoacrylate
adhesives (super glues), polyurethane adhesives,
and structural acrylic adhesives. Each type of
adhesive offers different properties, such as
curing time, strength, flexibility, and resistance
to temperature, moisture, and chemicals. The
choice of adhesive depends on factors such
as the application requirements, substrate
materials, and environmental conditions.

Adhesive bonding offers several advantages

for joining sheet metal assemblies, including
uniform distribution of stress, vibration damping,
corrosion resistance, and the ability to bond
dissimilar materials.

Sheet Metal Design Guide 17

 05 Designing for
Strength and Rigidity

Sheet Metal Design Guide 18

Factors Influencing Structural Integrity in Sheet Metal Parts

Achieving structural integrity in sheet metal parts Additionally, the design of the part plays a crucial
requires a thorough look at material selection, role in determining its structural integrity. Factors
design optimization, manufacturing processes, such as thickness and features like bends, holes,
and post-processing treatments. By taking these and fillets must be optimized to distribute stress
factors into account, designers and engineers can and minimize points of weakness. Properly
ensure that sheet metal parts meet stringent designed features, such as rounded corners
performance requirements, withstand operational and reinforcement ribs, help prevent stress
demands, and deliver reliable performance in concentrations and improve the overall
diverse applications. strength and durability of the part.

One of the primary factors is material selection, Manufacturing processes also influence the
as different metals and alloys offer varying levels structural integrity of sheet metal parts. Processes
of strength, ductility, and corrosion resistance. like bending, forming, welding, and assembly can
Choosing the appropriate material for the specific introduce residual stresses, distortion, and defects
application ensures that the part can withstand that may compromise the part's structural integrity
mechanical loads, environmental conditions, and if not properly controlled. Careful attention to
operational requirements without compromising process parameters, tooling design, and quality
its structural integrity. control measures is essential to minimize these
effects and ensure consistent part quality.
Factors such as surface finish, heat treatment,
and post-processing treatments can also impact
the structural integrity of sheet metal parts.
Surface imperfections, roughness, and residual
stresses resulting from subpar manufacturing
processes can affect fatigue life, corrosion
resistance, and overall performance. Proper
surface finishing and treatment methods help
mitigate these issues and enhance the structural
integrity and longevity of the parts.

Sheet Metal Design Guide 19

Reinforcement Techniques

Reinforcement techniques are essential for Beads and Hemming: Forming beads or hemming
enhancing the structural integrity of sheet metal edges of sheet metal parts increases their stiffness
parts, especially in applications subjected to high and resistance to bending or buckling. Beads are
loads, vibrations, or thermal cycling. By raised or indented lines pressed into the surface,
incorporating these reinforcement techniques into while hemming involves folding or bending the
sheet metal design and fabrication processes, you edge of the sheet over itself. These techniques
can ensure that your parts meet stringent increase the section modulus and bending stiffness
performance requirements, withstand mechanical of the part, improving its load-bearing capacity.
loads, and deliver reliable performance in your
particular applications. That being said, each Reinforcement Inserts: Inserts, such as threaded
technique offers unique advantages and inserts, rivet nuts, or clinch nuts can be installed in
considerations, and your choice depends on sheet metal parts to provide threaded or reinforced
factors such as part geometry, material properties, attachment points. These inserts distribute loads
and performance requirements. more evenly and prevent stripping or pull-out of
fasteners in high-stress areas. Reinforcement
Ribbing and Flanging: Adding ribs or flanges to inserts are commonly used in assemblies requiring
sheet metal parts increases stiffness and strength frequent disassembly and reassembly.
by distributing loads more evenly across the
surface. Ribs are raised features typically added Welded or Bonded Brackets: Welded or bonded
perpendicular to the main surface, while flanges brackets are additional metal components welded
are bent edges or lips that provide additional or bonded to sheet metal parts to provide
rigidity. These features help prevent buckling, reinforcement and attachment points for other
bending, and deformation under load. components. These brackets can be customized in
shape and size to suit your specific design
Gusset Plates: Gusset plates are flat, triangular, or requirements and offer increased strength and
rectangular plates that are welded or riveted to stability in critical areas.
sheet metal assemblies at junctions or corners.
They provide additional support and Folded Edges and Seams: Folding or bending the
reinforcement, particularly in areas prone to stress edges of sheet metal parts creates reinforced
concentration or fatigue failure. Gusset plates seams that improve stiffness and prevent edge
effectively redistribute forces and improve the deformation. Folded edges also provide a smooth
overall strength and stability of the assembly. surface finish and enhance the part's appearance
while adding structural integrity.

Sheet Metal Design Guide 20

Finite Element Analysis (FEA) for Evaluating Designs

FEA is a powerful tool for evaluating designs, Through FEA, engineers can simulate and predict
identifying potential issues, and ensuring that how a design will perform in real-world conditions,
engineering solutions meet performance such as mechanical loading, thermal cycling, and
requirements and regulatory standards. It involves fluid flow. It allows for the optimization of designs
dividing complex structures or components into by identifying areas of high stress, deformation,
smaller, finite elements and analyzing their or failure, guiding modifications to improve
behavior under various loading conditions. performance, reduce weight, or minimize
material usage.
In FEA, the structure is represented by a mesh of
interconnected elements, each defined by Key benefits of FEA include its ability to:
mathematical equations that describe its material • Analyze complex geometries
properties, geometry, and boundary conditions. By • Simulate multiple loading scenarios
solving these equations using numerical methods, • Iterate designs rapidly
FEA software calculates the stresses, strains,
displacements, and other mechanical responses FEA helps engineers make informed decisions,
within the structure. validate design concepts, and optimize
performance while reducing the need for
costly physical prototypes and testing.

Sheet Metal Design Guide 21

 06Designing for
Manufacturing Efficiency

Sheet Metal Design Guide 22

Nesting and Reducing Scrap and
Material Utilization Waste in Production

Nesting and material utilization both play a Reducing scrap and waste in production is
crucial role in designing for manufacturing essential for maximizing efficiency and minimizing
efficiency in sheet metal fabrication. By optimizing costs in sheet metal fabrication. Several strategies
part layouts, minimizing waste, and selecting can help achieve this, including designing parts
appropriate material sizes and thicknesses, with efficient nesting layouts, minimizing
designers can reduce costs, improve productivity, unnecessary features, and selecting appropriate
and enhance the overall competitiveness of their material thicknesses can help reduce scrap
manufacturing processes. and waste.

Nesting involves arranging multiple parts on Maximizing material utilization through effective
a single sheet of material in the most efficient nesting techniques, such as nesting software
manner possible to minimize waste and maximize algorithms, can minimize leftover material and
material utilization. By strategically positioning reduce scrap. Optimizing manufacturing processes,
parts close together and orienting them to such as cutting, bending, and welding, in order to
optimize cutting paths, designers can reduce minimize errors and rework can also help reduce
scrap, lower material costs, and improve overall scrap and waste.
efficiency. Advanced nesting software utilizes
algorithms to automatically generate optimized
layouts based on part geometries, quantities,
and material constraints.

Efficient material utilization goes hand in hand

with nesting and involves selecting sheet sizes and
material thicknesses that minimize waste while
meeting design requirements. Designers and
engineers must consider factors, such as part
geometry, nesting efficiency, material availability,
and cost when determining the optimal sheet size
and thickness for a given project. By selecting
standardized sheet sizes and thicknesses and
optimizing nesting layouts, designers can maximize
material utilization and minimize waste, leading to
cost savings and improved sustainability.

Sheet Metal Design Guide 23

Designing for Automated Fabrication Processes

By designing with the automated fabrication process in mind, engineers and designers can leverage
automation to improve productivity, quality, and consistency in sheet metal fabrication. The process
involves creating part geometries and features that are compatible with automated machinery and
workflows. You can do so through:

Feature Simplification

Simplifying part geometries and minimizing complex features can streamline automated fabrication
processes, reducing cycle times and improving efficiency.

Tolerance Management

Designing parts with appropriate tolerances ensures compatibility with automated machining and assembly
processes, minimizing the risk of errors and rework.

Standardization

Standardizing part designs and components across product lines can simplify programming and setup for
automated machinery, increasing flexibility and scalability.

Material Compatibility

Selecting materials that are compatible with automated fabrication processes, such as laser cutting,
CNC machining, and robotic welding, ensures optimal performance and quality.

Sheet Metal Design Guide 24

 07
Designing for Assembly

Sheet Metal Design Guide 25

Simplifying Assembly Processes Minimizing the Number of Parts

Designing parts with features that facilitate a To minimize the number of parts used in assembly,
simple assembly process, such as self-locating engineers and designers can employ proven
features and snap fits, can improve assembly strategies, such as part consolidation and modular
efficiency and reduce labor costs. design. Part consolidation involves combining
multiple components into a single part, reducing
assembly complexity and the number of required
fasteners. Modular design involves standardizing
components across product lines and utilizing
interchangeable modules, reducing the overall
number of unique parts and simplifying assembly
processes. Explore opportunities for incorporating
multi-functional features or integrating assembly
steps into part manufacturing processes to further
streamline assembly and reduce part count.

Designing for Ease of Handling

and Transportation

Designing for ease of handling and transportation

involves considering the size, weight, and shape
of components to facilitate safe and efficient
movement throughout the assembly and supply
chain processes. Achieve this by incorporating
features such as ergonomic handles, lifting points,
and packaging considerations that align with
industry standards and regulations. Additionally,
optimizing part geometries to minimize sharp
edges or protrusions reduces the risk of injury
during handling and ensures compatibility with
standard packaging and shipping methods.

Prioritizing ease of handling and transportation

in design means improving operational efficiency,
reducing labor costs, and enhancing
workplace safety.

Sheet Metal Design Guide 26

 08 Cost Considerations

Sheet Metal Design Guide 27

Factors Affecting the Cost of Sheet Metal Parts

Material Cost

The choice of material significantly impacts the overall cost of sheet metal parts. Different metals
and alloys vary in price, with factors such as material grade, thickness, and availability affecting cost.

Complexity of Design

The complexity of part geometry, htures, and tolerances directly affects manufacturing time, tooling
requirements, and labor costs. Simple designs with fewer features and tight tolerances tend to be less
expensive to produce than complex, intricate designs.

Manufacturing Processes

The selection of manufacturing processes, such as cutting, bending, welding, and finishing, influences
production costs. Each process incurs specific tooling, setup, and operating costs that contribute to
the overall cost of the part.

Volume and Batch Size

Production volume and batch size play a significant role in determining the cost per part. High-volume
production runs typically benefit from economies of scale, resulting in lower unit costs, while small-batch
or custom orders may incur higher per-part costs due to setup and handling charges.

Quality Requirements

Quality standards, inspection procedures, and testing requirements can impact the cost
of sheet metal parts. Meeting stringent quality requirements may involve additional testing,
inspection, or certification processes that add to the overall cost of production.

Sheet Metal Design Guide 28

Strategies for Cost Reduction Balancing Cost and Performance
in Sheet Metal Design in Design Decisions

To reduce costs in sheet metal design, several Balancing cost and performance in design
strategies can be implemented throughout the decisions is a crucial aspect of product
product development process. First, optimizing development, especially in sheet metal fabrication.
part geometry and simplifying designs can Carefully weigh the trade-offs between
minimize material usage and reduce manufacturing cost-effectiveness and meeting performance
complexity, resulting in lower production costs. requirements to achieve the optimal balance.
Standardizing components and leveraging This involves identifying key performance criteria,
common features across product lines can also such as strength, durability, and functionality, and
streamline manufacturing processes and reduce determining the most cost-efficient methods for
the need for unique tooling or setups, further achieving them.
reducing costs.
By prioritizing critical performance attributes
Additionally, selecting cost-effective materials and and optimizing design features, materials, and
thicknesses that meet performance requirements manufacturing processes, one can minimize costs
while minimizing waste can result in significant cost without sacrificing product quality or functionality.
savings. Implementing design for manufacturability Additionally, considering factors such as product
principles, such as designing parts with ease of lifecycle costs, maintenance requirements, and
fabrication and assembly in mind, can further customer expectations can help ensure that
enhance efficiency and reduce labor costs. cost-conscious design decisions align with
long-term performance and value.
Finally, collaborating closely with suppliers and
manufacturers to identify opportunities for Ultimately, achieving the right balance between
process improvement and value engineering can cost and performance requires a comprehensive
help identify additional cost-saving measures understanding of design objectives, manufacturing
throughout the design and production lifecycle. capabilities, and market dynamics, as well as
effective collaboration between design, engineering,
and procurement teams throughout the product
development process.

Sheet Metal Design Guide 29

Trust Rapid Axis For Your
Sheet Metal Fabrication Needs
Sheet metal design holds paramount importance across many industries, offering
unparalleled versatility, efficiency, and functionality in the fabrication of diverse
components and assemblies. Its adaptability to various shapes, sizes, and
configurations makes it indispensable in applications ranging from automotive
and aerospace to electronics and architecture.

Sheet metal design is not merely about creating parts; it's about engineering
solutions that meet stringent performance requirements, withstand harsh
environments, and optimize manufacturing processes. From precise bend
radii to intricate hole placements, every aspect of sheet metal design
contributes to the functionality, durability, and aesthetics of the final product.

For projects requiring sheet metal fabrication expertise, entrusting

your endeavors to a trusted partner like Rapid Axis can make all the
difference. With our wealth of experience, cutting-edge technology, and
commitment to excellence, Rapid Axis stands ready to bring your sheet
metal projects to fruition. Whether you require design assistance,
prototyping, or large-scale production, Rapid Axis offers the expertise
and resources to deliver superior results efficiently and cost-effectively.

Don't let your sheet metal projects be constrained by limitations.

Embrace the possibilities with Rapid Axis as your partner.
Together, let's turn your visions into reality.

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