SOLIDWORKS Exercise 1

Sheet Metal from Flat

Exercise 1: Create this part using the dimensions

Sheet Metal provided. This is a sheet metal part that is
from Flat designed in the flat.
This exercise uses the following skills:
 Designing from the Flat
 Sketched Bend Feature
Units: MMGS

Procedure
1 New part.
Begin a new part using the Part_MM template.
2 Profile sketch.
Using the Front plane, sketch the full profile of the flat pattern. Use a
centerline and mirroring to create the geometry.

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Exercise 1 SOLIDWORKS
Sheet Metal from Flat

3 Sheet metal plate.

Create a Base Flange with 15 Gauge steel.
Set the Bend Radius to 1.905mm.

4 Add a cut.
Add a circular cut, dimensioned as
shown.
5 Add a hole wizard feature.
Add Ø5mm holes dimensioned as
shown.
The holes are symmetrical across the
vertical centerline.

6 Add bend lines.

Select the front face
of the model and
sketch bend lines.

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SOLIDWORKS Exercise 1
Sheet Metal from Flat

7 Create sketched bends.

Click Sketched Bends and
choose the center portion of the
face as the Fixed face.
Add all bends as Bend
Centerline with 90° bends,
bending up.

8 Save and close the file.

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Exercise 2 SOLIDWORKS
Jogs and Hems

Exercise 2: Use sheet metal features to complete the

Jogs and Hems part as shown.
This exercise reinforces the following
skills:
 Base Flange/Tab
 Cuts in Sheet Metal
 Edge Flanges
 Jog Feature
 Hem Feature
 Corner Relief
 Flat Pattern Settings
Units: MMGS
Procedure
1 New part.
Create a new document using the Part_MM template.
2 Base Flange.
Create a sketch and base flange.
The Depth is 90mm.
The material is 14 gauge steel and
thickness is applied to the outside of
the sketch.
The bend radius is 2.54mm
Use a Rectangular auto relief with a
0.5 relief ratio.
3 Optional: Modify appearance.
Edit the appearance of the part as
desired.

4 Cut.
Create a cut as shown.

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SOLIDWORKS Exercise 2
Jogs and Hems

5 Right-most edge flange.

Add an edge flange as shown using the
following settings:
 Use default radius
 Angle = 90°
 Flange Length = 50mm from
Outer Virtual Sharp
 Flange Position =
Material Outside
 Trim side bends = cleared
6 Jog.
Sketch a jog line on the back face of the flange
as shown.
Fixed Face
Create the Jog using:
 Use default radius
 Offset Distance = 4.75mm
 Dimension position =
Outside offset
 Fix projected length = On
 Jog Position = Bend centerline
 Jog Angle = 70°

Click OK .

7 Left-most edge flange.

Add an edge flange as shown using the same
settings as step 5 on page 5, except with a
Flange length of 52mm.

Click OK .

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Exercise 2 SOLIDWORKS
Jogs and Hems

8 Hem.
Add a hem to the outside edge of the
flange using:

 Material inside
 Type = Open
 Length = 9.5mm
 Gap Distance = 0.75mm

Click OK .

9 Corner Relief.
Click Corner Relief .
Click Collect all corners.

For Relief type select Constant Width .

This relief type continues the width of the
gap into the bend areas for the relief.

Click OK .

10 Holes.
Use the Hole Wizard to create M3
Screw Clearance Holes, Through All,
dimensioned as shown.

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SOLIDWORKS Exercise 2
Jogs and Hems

11 Examine the flat pattern.

The orientation of the flat pattern can be
improved. Also, the holes will be added
after the part is formed, so should be
removed from the flat pattern.
12 Edit the flat pattern feature.
Expand the Flat-Pattern folder. Select
the Flat-Pattern1 feature and
Edit Feature .
Replace the Fixed face with the bottom
inside face of the part.
Click to activate the selection box for
Faces to Exclude. Select the 6 hole
faces.

Click OK .
13 Results.
The flat pattern now
unfolds from the bottom
face and the holes have
been removed.
14 Exit Flatten.

15 Edit Material.
Edit the material of the part to be AISI 316 Stainless Steel Sheet.
Optional: Use the Appearances tab in the Material dialog to clear the
option to Apply appearance of the material.

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Exercise 2 SOLIDWORKS
Jogs and Hems

16 Modify cut list item properties.

Expand the Cut List folder. Right-click the Cut List Item
folder to access Properties.
Modify the Description to be 14 Gauge Sheet.
17 Create drawing from part.
Click Make Drawing from Part .
Choose the A_Size_ANSI_MM template.
Create the drawing views and cut list table as shown.
Tip Use Model Items to add the hole callout and dimensions. Use the
cut list table template SM CL with Blank Size created on page 96.

18 Save and close all files.

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SOLIDWORKS Exercise 3
Fold & Unfold

Exercise 3: Use tools to flatten selected bends and add

Fold & Unfold features that are visible in both the formed
and flattened states of the model.
This exercise uses the following skills:
 Unfold and Fold
Units: MMGS

Procedure
1 Open part.
Open the part Fold and Unfold.
2 Optional: Part Reviewer.
This model has been saved with
comments describing how the part was
built. Hover the cursor over features in
the tree or use Part Reviewer from
the Evaluate toolbar to examine the
features and comments.

3 Unfold.
The edges of the bend region need to be broken with a radius. The bend
will need to be unfolded to add this feature.
Also, the dimensions of the slot cut should be defined in the flat.

Click Unfold and select the back

planar face as the Fixed face.
For Bends to unfold, select the three
bend regions surrounding the fixed face
as shown.

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Exercise 3 SOLIDWORKS
Fold & Unfold

Click OK .

4 Create slot cut.

Sketch the profile as shown and create an Extruded Cut .
Tip The Origin is located at the Midpoint of the slot’s top edge.

5 Add fillets.
Add a Fillet feature to the edges of the bend
regions as shown. Set the radius equal to the
existing global variable by typing an equal sign (=)
in the dimension field and choosing Global
Variable, Corner_R from the menu.

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SOLIDWORKS Exercise 3
Fold & Unfold

6 Fold.
Click Fold .
Click Collect All Bends.

Click OK .

7 Examine the flat pattern.

8 Save and close the part.

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Exercise 4 SOLIDWORKS
Conical Swept Flange

Exercise 4: Create the conical sheet metal part shown

Conical Swept using a swept flange feature.
Flange This exercise uses the following skills:
 Edge Flanges
 Swept Flange
 Swept Flange Flat Pattern Options
Units: MMGS

Procedure
1 Open the existing part Conical.
It contains two sketches which are set to
create a conical swept flange.

2 Insert Swept Flange feature.

Click Insert, Sheet Metal, Swept Flange .
Select the profile and path sketches.
Select Cylindrical/Conical Bodies.
Select one of the conical profile sketch elements as the Cylindrical/
Conical edge.

Tip The flat pattern orientation will vary depending on the edge selection
(if they are at different angles).

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SOLIDWORKS Exercise 4
Conical Swept Flange

3 Sheet Metal Parameters.

Click Use gauge table and select the SAMPLE TABLE -
ALUMINUM.
Select Gauge 20, with a bend radius of 1.00mm.

Click OK .
4 Add Edge Flange feature.
Click Insert, Sheet Metal,
Edge Flange .
Select the bottom inner edge.
Keep Flange Angle to 90deg and
Flange Length to 20mm.

Click OK .

5 Flatten.
Flatten the part to see the flat shape
based on the cylinder / cone option.
Optional: For contrast, edit the
feature and deselect this option.
Also try different edge selections.

6 Save and close all files.

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Exercise 5 SOLIDWORKS
Lofted Bends

Exercise 5: Use different lofted bend options to produce sheet metal transitions.
Lofted Bends

This exercise uses the following skills:

 Lofted Bends
 Bent Lofted Bends
 Formed Lofted Bends
Units: MMGS
Procedure
1 Open part.
Open the part Lofted_Bends.
This part contains the profiles that will be used to create the sheet metal
transition.
2 Bent Lofted Bend.
Click Lofted-Bend .
Select the profiles near
common points to orient the
loft.
Set the Manufacturing
Method to Bent.
3 Faceting Options.
To control the facets in the
bend regions, select Segment
Angle and set the Facet
Value to 15deg.
4 Sheet Metal Parameters.
Click Use gauge table and select SAMPLE TABLE - STEEL.
Select 12 Gauge thickness and 5.080mm bend radius. The material
should be applied to the outside of the profiles.

Click OK .

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SOLIDWORKS Exercise 5
Lofted Bends

5 Examine flat pattern.

Click Flatten .
Each bend region includes
multiple bend lines.
Exit flatten.

6 Save the part.

7 Save as Lofted_Bends_Formed.
To create a version of the transition as a formed lofted bend, first save
the part as a new name.
Click File, Save As.... and create a new file named
Lofted_Bends_Formed.
8 Delete Lofted Bends1 feature.
Once created, a lofted bend feature cannot be changed from Bent to
Formed. The feature needs to be deleted and re-created.
Selected the Lofted Bends1 feature and press Delete. Click Yes to
confirm the deletion of all child features.
9 Formed Lofted Bend.
Click Lofted-Bend .
Select the profiles near common points to
orient the loft.
Set the Manufacturing Method to
Formed.
The material should be applied to the
outside of the profiles.

Click OK .
10 Examine flat pattern.
Click Flatten .
The profiles do not meet the
conditions required to generate
bend lines and bend regions.
Exit flatten.

11 Save and close all files.

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Exercise 6 SOLIDWORKS
Using Symmetry

Exercise 6: Take advantage of the symmetry of

Using the model pictured by utilizing Mirror
Symmetry features. Custom reliefs will also be
added to the part.
This exercise uses the following
skills:
 Cuts in Sheet Metal
 Tab Features
 Break Corner/Corner Trim
 Jog Feature
Units: MMGS
Procedure
1 Open part.
Open the part Using_Symmetry. It is a sheet
metal part that contains base flange and edge
flange features.

Manual Relief Cut The upper edge flange is in need of a relief cut at the
side bend. Rather than use the option to
Trim Side Bends, which would leave a large
opening, a custom relief will be created manually
using an Extruded Cut. This will allow only a
portion of the bend area to be removed.

2 Sketch.
Sketch a rectangle using vertices and
edges to fully define it.

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SOLIDWORKS Exercise 6
Using Symmetry

3 Extrude Normal Cut.

Create a cut feature using the Normal cut and
Link to thickness options.
The cut is projected to the depth specified, then
cut normal to the material thickness.

4 Mirror.
At this point in the design, all features that are symmetrical from left to
right have been completed.

Click Mirror . Use the face indicated in the picture below as the
mirror plane.

Click Bodies to Mirror and select the sheet metal body. Click OK .

5 Tab.
Add a Tab , sketching on the left vertical flange.

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Exercise 6 SOLIDWORKS
Using Symmetry

6 Break corners.
Click Break Corner .
Select the Chamfer option
and set the Distance to
7mm.
Select the face as shown.

Click OK .

7 Tombstone relief cut.

Create another manual relief cut using the
profile shown and an Extruded Cut .
Set the end condition to Blind and use
Link to thickness.

8 Sketch for Jog.

Create a sketch on the flat face
created by the tab.
Sketch a vertical line and dimension
as shown.

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SOLIDWORKS Exercise 6
Using Symmetry

9 Face selection.
Click Jog , and select the face to
the left of the sketched line. The
arrow should point in the direction
shown.

10 Jog settings.
In the PropertyManager, set the following:
 Use default radius = On
 End condition = Blind
 Depth = 0.5mm

 Dimension position = Inside Offset

 Fix projected length = On

 Jog position = Bend Centerline

 Jog Angle = 30°

Click OK .

11 Result.
The resulting jog feature creates bends and flats in the flange.

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Exercise 6 SOLIDWORKS
Using Symmetry

12 Tab.
Add another Tab using the right
vertical flange for the sketch plane.
Dimension the overlap.

13 Break corners.
Add 7mm chamfers to the tab face
using Break Corner .

14 Mirror feature.
Mirror the existing tombstone relief
cut (step 7 on page 18) about the
Right Plane.

15 Hole wizard.
Use the Hole Wizard to create 3mm diameter holes using the
Through All end condition. Dimension as shown.

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SOLIDWORKS Exercise 6
Using Symmetry

16 Mirror.
Mirror the body again using a sheet metal face at the back of the part.

Sheet Metal The SOLIDWORKS Design Library

Library Features includes several library features
representing common sheet metal cuts.
These can be added to a model by using
drag and drop from the Task Pane.
The sheet metal library features are
located in the Design Library under
features, Sheetmetal.

17 Access the sheet metal library features.

Click the Design Library tab in the Task Pane.
Expand design library, then features, and select the Sheetmetal
folder.

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Exercise 6 SOLIDWORKS
Using Symmetry

18 Drag and drop.

Drag and drop the key-hole slot library
feature from the Sheetmetal folder
onto the face shown.

19 Edit sketch.
Click Edit Sketch to locate the feature.

Add a Colinear relation between the Right

Plane and the centerline.
Add the 15mm dimension as shown.
Click Finish.

Tip Library features appear with the

library books icon in the
FeatureManager design tree. If
desired, library features can be
dissolved from the shortcut menu in
order to appear as conventional
features in the tree.

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SOLIDWORKS Exercise 6
Using Symmetry

20 Second instance.
Add a second instance of the key-hole slot. Either drag and drop again
from the library, or use a linear pattern.

21 Flatten.
Click Flatten to check
the final flat pattern.

22 Exit flatten.

23 Save and close the

file.

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Exercise 6 SOLIDWORKS
Using Symmetry

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