Ultimate Sheet Metal Design Hacks for Engineers

Material
Thickness
The thickness of sheet metal is an important factor that affects its properties and performance. Here are some of the key reasons why thickness matters in sheet metal:
Strength and durability: Thicker sheet metal is generally stronger and more durable than thinner sheet metal. This is because thicker sheet metal has more material to resist bending, warping, and other forms of deformation.
Stiffness: Thicker sheet metal is also stiffer than thinner sheet metal. This means that it is more resistant to bending and buckling.
Weight: Thicker sheet metal is heavier than thinner sheet metal. This can be a factor to consider when designing and manufacturing products.
Corrosion resistance: Thicker sheet metal is generally more corrosion-resistant than thinner sheet metal. This is because thicker sheet metal has more material to protect the underlying metal from the elements.
Thermal conductivity: Thicker sheet metal has lower thermal conductivity than thinner sheet metal. This means that it is a better insulator and can help to reduce heat transfer.
Acoustics: Thicker sheet metal can help to reduce noise levels. This is because thicker sheet metal absorbs sound waves more effectively than thinner sheet metal.
Cost: Thicker sheet metal is generally more expensive than thinner sheet metal. This is because it requires more material and is more difficult to manufacture.
Bend radi
Bend radius is a critical parameter in sheet metal fabrication. It determines the ability of a sheet metal part to withstand bending without cracking or tearing. A proper bend radius ensures the structural integrity, functionality, and aesthetic appeal of the final product. It also influences factors like material thickness, grain direction, and the type of bending process used.
If you are not sure what radius to use watch out my video on how to select Inside radius in sheet metal.
Bending Angle
Bending angle is very important because you need to understand how much fold you can achieve with the tools available at your place.
Bend relief
Choosing the right bend relief will go a long way in mass production and the look.
K -Factor
Understanding how K factors affects the material bending proporties will help you get to the perfect fold every single time. This is the factor most designers get wrong and the workshop suffers for their mistakes. If you want to know more about K factor please check out my other videos on K factor which will help you understand it easily.
Hole Distance and size
When you have holes in your sheet metal design make sure they are in the safe distance from falling in the V gap. Otherwise metal will deform and you will not get a perfect hole in the desired place. It is also important for you to know how we are going to cut those holes So ideally Any fabricator will prefer hole dia should me minimum the thickness of the metal.
Bend Distance
Every V block has a minimum bend distance . it is also called as minimum flange distance. Ideally it is calculated by V size /2 +1 for thin metal V size /2 +2 for thick metal.
But knowing your limitations will help you design the perfect parts.
Clearance
If your part requires other processes like stamping or punching . make sure you consider the distance and tooling clearance for designing the part.