Sheet Metal Prototyping Best Practices

Designing for sheet metal prototyping involves several key considerations to ensure manufacturability, functionality, and cost-effectiveness. One fundamental aspect is selecting the appropriate material thickness. This choice impacts the part's strength, weight, and the feasibility of forming processes. It's essential to maintain uniform thickness throughout the part to prevent issues during fabrication and ensure consistent quality .​ Another critical factor is the design of bends and flanges. Incorporating standard bend radii and reliefs helps mitigate the springback effect and reduces the risk of metal tearing. Utilizing standard die sets, such as 0.80 mm (0.030″) tools for internal corners, can be advantageous. Alternatively, consulting with your fabricator about the available tools is essential to ensure compatibility .​ Additionally, accounting for features like holes and slots is crucial. It's recommended to place holes and slots at least 3 mm away from bend lines to prevent deformation during bending. This distance helps maintain the integrity of the part and ensures accurate hole placement .​ By adhering to these best practices, you can optimize your sheet metal designs for prototyping, leading to more efficient production processes and higher-quality prototypes.