Avoid Common Sheet Metal Design Errors
Save time and costs on your next prototype. Learn the vital design rules for bends, finishes, and materials from the experts at TLD.
Why Design Accuracy Matters
Designing sheet metal prototypes requires attention to detail. By learning from common mistakes, you can ensure your designs are functional, durable, and aesthetically pleasing—avoiding costly re-works during manufacturing.
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6 Critical Design Errors to Watch
1. Cutouts Too Close to Bends
Placing cutouts near bend lines leads to stretching or flaring during the bending process. This distorts the hole shape and causes fitment issues for inserted components.
The Fix
Adhere to minimum bend rules. Maintain adequate distance between cutouts and bend lines. If closer placement is unavoidable, design a relief notch across the bend line to preserve the cutout's integrity.
2. Selecting the Wrong Finish
An inappropriate finish destroys appearance and fails to protect against corrosion. Neglecting environmental factors like salt spray or UV exposure leads to rapid degradation.
The Fix
Analyze the intended environment. Choose Powder Coating for durability and color, or Chemical Conversion for conductivity. Balance aesthetics with practical needs like temperature resistance.
3. Forgetting Finish Thickness
Powder coating adds 0.003"-0.005" per side. Ignoring this leads to ill-fitting assemblies where parts become too tight or holes become too small.
The Fix
Always factor in finish buildup when specifying tolerances. Consult with fabricators on material specifications to balance strength, weight, and assembly fit.
4. Disregarding Bend Radius
Tight bend radii create weak points and fractures. Placing features too close to bends risks material distortion.
The Fix
Follow the 4T Rule: Keep holes and slots at least 4 times the material thickness away from bend lines. Consult bend radius charts specific to your chosen alloy.
5. Choosing the Wrong Metal
Overlooking factors like heat, corrosion, or conductivity causes failure. E.g., using regular steel in high-humidity environments leads to rust.
The Fix
Assess properties carefully. Use Stainless Steel for corrosion resistance, or Aluminum for heat dissipation and weight reduction. Consider tensile strength loss at high temperatures.
6. Not Specifying Hardware
Vague drawings lead to incompatible screws or rivets. This causes delays, assembly weakness, and potential corrosion (galvanic reaction).
The Fix
Include comprehensive hardware specifications (Type, Size, Material) in your CAD design. Ensure hardware compatibility to handle vibration and dynamic loads.
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