How to Design Good Sheet Metal Parts

We follow Sheet metal design guidelines to ensure the quality and manufacturability of sheet metal enclosures. As a result, you can deliver the product at a low cost and faster timeline. It is difficult to follow all sheet metal design guidelines for complex sheet metal parts.

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Therefore, exceptions can be there for complex sheet metal parts. However, it is important to test these exceptions before the design release. In this article, we will explore sheet metal design guidelines while considering a press bending machine.

In today's fast-paced production environment, effective sheet metal fabrication is critical for achieving volume success.

This fabrication process involves transforming large metal materials such as alloys and aluminum into smaller components necessary for various products.

For instance, consider how a block of steel could be converted into military-grade ammunition—this illustrates the versatility of sheet metal fabrication across diverse sectors, including military defense, lighting, and home improvement.

Fundamentals of Sheet Metal Forming

Sheet metal fabrication involves changing metal sheets into usable parts through processes such as punching, cutting, stamping, and bending.

To execute these tasks, 3D CAD files are converted into machine code, allowing machines to accurately cut and structure the sheets into the desired final product.

Two critical factors to assess before commencing fabrication are bending and wall thickness.

Bending Techniques

Bending is achieved using a press brake machine, which applies sufficient force to the metal sheet. This pressure causes the sheet to bend at specific angles to yield the final product. The K Factor is a measurement used in this context, indicating the extent of metal stretching during bending.

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Importance of Wall Thickness

The wall thickness of a sheet metal part can dictate the possibility of its manufacture. It’s vital to maintain a consistent thickness throughout the component. Generally, sheet metal parts can be formed with a thickness ranging between 0.9mm to 20mm.

When assessing wall thickness, utilizing a single sheet with punches is a recommended practice.

Advantages of Laser Cutting

Laser cutting stands out as one of the most efficient methods for slicing through metal sheets. This technique utilizes a high-energy laser beam to cut through various materials, including metals, aluminum, wood, plastic, and rubber.

Using computer numerically controlled programming (CNC), the laser accurately dictates the design and layout for metal sheet cutouts, with material thickness tolerance reaching up to 20mm. Because CNC technology significantly minimizes labor costs, laser cutting is often deemed an economical choice.

Measuring Tolerance Levels

When deciding if sheet metal fabrication is appropriate for a project, it's important to consider production thickness tolerances specific to the material. These include:

• General Tolerances: Wall thickness, hole diameters, and bends all need careful consideration. Parts with a thickness of 0.9mm to 20mm can typically be manufactured with a +/- 1-degree tolerance for bends. For laser cutting, hole diameters should exceed the material thickness.
• Curls: To ensure safe handling, curls should maintain a minimum outside radius of two times the material thickness.
• Countersink Holes: It’s advisable to keep countersink depths below 0.6mm of the total material thickness.
• Countersink Tolerances: Standard angles for countersinks should reflect diameters between 2.3mm and 12.7mm, with a tolerance of +/- 0.254mm for the major diameter.

H&S Manufacturing: Expertise You Can Trust

With over 40 years in the industry, H&S Manufacturing is adept at maintaining precise tolerances, delivering high-quality Custom Sheet Metal Fabrication Services, and providing rapid multi-tool solutions tailored to customer requirements.

Whether it's precision laser cutting or custom fabrication, H&S Manufacturing ensures that clients receive knowledgeable support and resources.

Reach out today to learn more or to request a personalized quote.

Contact us to discuss your needs regarding Custom Sheet Metal Fabrication Services. Our experienced sales team can guide you in selecting the most suitable options.