Sheet Metal
Fabrication
The complete design guide
Table of contents
3 Overview
How sheet metal fabrication works
Sheet metal fabrication
Benefits of sheet metal fabrication
Limitations of sheet metal fabrication
8 Forming Basics
Press brake forming
Bending
Springback
Bend relief and height
Forming near holes
14 Cutting
Laser cutting
Plasma cutting
17 Design Guidelines
Curls
Hems
Holes and slots
Notches and tabs
22 Materials
24 Additional Resources
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Overview
How sheet metal fabrication works
Sheet metal fabrication is a subtractive manufacturing process that create a part from thin metal
sheets into cuts, bends, and formed parts or assemblies directly from your CAD file.
Materials include aluminum, stainless steel, cold-rolled steel, and beryllium copper. Each metal of
alloy is selected based on mechanical properties, aesthetics, and performance characteristics based
on part or component specifications.
How sheet metal fabrication can help you:
• Choose materials for desired properties: aesthetics, corrosion resistance, higher
strength-to-weight ratio, etc...
• Remove the need for tooling with more automated prototype-to-production sheet metal
fabrication solutions.
• Save production costs by eliminating potential design errors that can negatively impact
part maneuverability.
• Increase accuracy for rapid prototypes in quantities as low as one, or for higher-volume
production.
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Sheet metal fabrication
Cutting
Laser, plasma, waterjet, shearing, and sawing...we
combine traditional and advanced cutting methods
for just about any kind of metal or alloy with a wide
variety of sheet stock sizes, tolerances, and
thickness to ensure your design integrity.
Stamping
From bending and punching to progressive
die-stamping, we can ensure every one of your parts
meets your performance expectations - even for
complex designs for mass production.
Welding
MIG, TIG, robotic... we offer a wide range of welding
processes, materials, and finshes based on your
specific application, including any post-processing
required for your technical specifications.
Value-add hardware
We have more hardware options to alleviate your
supply chain headaches, including standos,
threaded inserts, threaded nuts, captive screws,
pins, and more based on your supply chain
requirements.
Finishing
Powder coating, buff polishing, sand blasting,
brushing plating, and a wide selection of finishing
levels available for all processes to produce targets
ranging from unfinished to photo-realistic results.
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Benefits of sheet metal fabrication
Versatility
There are a wide variety of materials that can be used in sheet metal fabrication, like steel,
aluminum, brass copper and more. Sheet metal fabrication is also suitable for a wide range of
industries including automotive, aerospace, electronics, and more.
Cost-effective
There is less material waste in sheet metal fabrication compared to other methods. It is also an
economical solution for both small and large-scale production runs.
Strength and durability
Many of the sheet metal fabrication metals offer significant strength while remaining lightweight.
There is also a lot of corrosion-resistant materials, especially with treatments like galvnizing.
Precision and accuracy
The use of modern CNC machinery ensures high precision and repeatability, and also sheet metal
fabrication is capable of achieving tight tolerances for complex parts.
Speed and efficiency
Sheet metal fabrication is able to meet quick turnaround times for prototypes and final products. It
also has high production speeds for processes like stamping, laser cutting, and bending.
Customization and flexibility
Sheet metal fabrication allows for creating complex shapes and designs, and it is easier to make
design modifications without significant cost increases.
Surface finishes
Sheet metal fabrication has options for various finishes such as painting, powder coating, anodizing,
and more to improve aesthetics and functionality.
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Limitations of sheet metal fabrication
Material thickness constraints
Sheet metal fabrication materials are not suitable for very thick or very thin materials beyond certain
limits.
Initial setup cost
There is a high initial setup cost for the custom tooling and machinery for sheet metal fabrication.
Complexity and design restrictions
Some complex shapes may be difficult or impossible with sheet metal fabrications, and there are also
limitations on shape bends and very tight radii.
Material properties
Certain metals may be brittle and prone to cracking under stress, and high thermal conductivity of
metals ban poses challenges in welding and other thermal processes.
Precision limitations
Accumulation of tolerances can affect the final assembly if not managed properly.
Surface treatment
The need for additional surface treatments or coatings to prevent corrosion and improve appearance
can add to costs and processing time.
Environmental concerns
Scrap metal and waste materials can be an environmental concern if not recycled properly.
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Forming Basics
Press brake forming
Press brake forming is the process where metal is bent or formed into shapes. The process works
when a die and a punch are used to bend the sheet of metal.
This is most often used to form parts from ferrous alloy sheets and plates. Press brake forming is
great for both prototype and production runs.
The maximum sheet thickness is ideally less than 6.5mm, but thickness up to 25mm.
Bending
Bending is a process where a force is applied to sheet
metal which causes it to bend at an angle and form the
desired shape. Bends can be short or long depending on
the design requirements.
Bending is performed by the press brake machines, which
are available in a variety of sizes and lengths, from 20-200
tons.
Parts to be bent are supplied as flat patterns with
the bending information, including bend etches or
notches.
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Bending
Bend line - The straight line on the surface of the
sheet, on either side of the bend, that defines the
end of the level flange and the start of the bend.
Bend radius - The distance from the bend axis to
the inside surface of the material, between the
bend lines.
Bend angle - The angle of the bend, measured
between the bent flange and its original position, or
as the included angle between perpendicular lines
drawn from the bend lines. Sometimes specified
as the inside bend radius. The outside bend radius
is equal to the inside bend radius plus the sheet
thickness.
Neutral axis- The location in the sheet that is neither stretched nor compressed, and therefore
remains at a constant length.
Bend allowance- The length of the neutral axis between the bend lines or the arc length of the bend.
The bend allowance added to the flange lengths is equal to the total flat length.
K-factor - The location of the neutral axis in the material, calculated as the ratio of the distance of the
neutral axis (T), to the material thickness (t). The K-factor is dependent on several factors (material,
bending operation, bend angle, etc..) and it is greater than 0.25, but not greater than 0.50.
180*(Allowable Bend) r
K= -
π *(Bend Angle) *T T
K-factor Chart
Radius Soft/Aluminum Hard/Stainless Steel
Air Bending
0-t .33 - .38 .40
y - 3*t .40 - .43 .45
3*t. - > 3*t. .50 - .50 .50
Bottom Bending
0-t .42 - .44 .46
y - 3*t .46 - .47 .48
3*t. - > 3*t. .50 - .50 .50
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Springback
Springback is what occurs when a metal is bent. When the bending force is distributed across the
surface is not enough to overcome the material’s modulus of elasticity, elastic deformation occurs,
not plastic deformation.
This elastic deformation impedes permanent deformation needed for a bend to remain.
Interestingly, near the geometrical center of sheet metal, there is a zone with low stress that only
experiences elastic deformation, even when under large bending forces. This means that this part is
susceptible to springback.
As the stiffness of a material increases, the amount of springback you can expect increases. As a
general rule of thumb, this is the maximum amount of springback that may occur (you should plan for
this variation when designing sheet metal parts):
• Soft metals like copper and aluminum: 0.5°
• Steel: to 1°
• Stainless steel: 3°
Bend angle also plays a crucial role. The smaller the relative effect on the elastic area in the neutral
zone, the smaller the springback. This is particularly true with small bend angles and small bend radii
(a sharp tool).
In general, you can expect less springback for a sharper tool, smaller bend angles, and smaller bend
radii.
The expected springback may be calculated as follows:
D= springback angle expected
R R= radius of the bend angle
D=a t= sheet metal thickness
2.1*t
a= correction factor
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Bend relief and height
When a bend is made close to an edge the material may tear unless bend relief is given.
The image to the left shows a torn part, while the
part on the right shows bend reliefs cut into the part.
The depth of the relief should be greater than the
radius of the bend. The width of the relief should be
a material thickness or greater, preferably a
material thickness + 1/64”.
Bend height should be at least twice the thickness of the sheet metal plus the bend radius.
H= 2t + r
If the bend height is too small, it will result in deformation and low bending quality.
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Forming near holes
When a bend is made too close to a hole, the hole may become deformed. To save the cost of
punching or drilling in a secondary operation, the following formulas can be used to calculate the
minimum distance required:
As a rule of thumb, the distance from the outside of the material to the bottom of the cutout should
be equal to the minimum flange length as prescribed by the air bend force chart.
For a hole <1” in diameter the minimum distance “D” = 2T+R
For a slot or hole >1” diameter then the minimum distance “D” = 2.5T +R
When using a punch press, or laser cutting, holes should never be less than that of the material
thickness.
D= Minimum distance
T= Material thickness
R= Bend radius
Feature Type Minimum distance guidelines
Between hole and a bend ±2.5 times the material length + bend radius
Between slot and a bend ±4 times the material thickness + bend radius
Between a hole or slot and edge ±2 times the material thickness
Minimum distance between holes ±2-3 times the material thickness
Between an extruded hole and an edge ±3 times the material thickness
Between an extruded hole and bend ±3 times the material thickness + bend radius
Between semi-pierced hole and a bend ±3 times the material thickness + bend radius
Between semi-pierced holes ±8 times the material thickness
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Cutting
Laser cutting
Laser cutting is a type of production that uses a
laser to cut different metals. The laser has a high-
energy beam that easily burns through the
material.
Localized Hardening
Localized hardening takes place on the edges where the laser has cut. This hardening produces a
durable and smooth edge without the need for finishing after using the laser cutter.
Distortion
The heat-affected zone (HAZ) is produced during laser cutting. In carbon steel, the higher the
hardenability, the greater the HAZ. Distortion from laser processing is a result of the sudden rise in
temperature of the material near the cutting zone.
Distortion is also created by the rapid solidification of the cutting zone.
Hole diameter
The entry diameter is larger than the exit diameter, creating a slightly tapered hole. Minimum hole
sizes are related to stock thicknesses and can be as low as 20% of the stock thickness.
Kerf
In laser cutting, “kerf” refers to the width of the
material that is removed by the laser beam as it
cuts through the sheet metal. It is a crucial
consideration in sheet metal fabrication because it
affects the precision and fit of the final product.
The kerf size is influenced by various factors,
including the type of material, the thickness of the
sheet, the laser power, and the cutting speed.
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Plasma cutting
While handled plasma cutters are available, a CNC
plasma cutter is the best option for cutting parts.
In plasma cutting, a gas is superheated with an
electric arc and compressed to the 4th state of
matter, plasma that flows through the sheet metal.
Superheated means up to 40,000°F; the electric arc
is about 5,000 VAC.
A precision CNC plasma cutter has a uniquely
shaped shield cap and orfice diameter to reduce the
plasma arc, resulting in a smaller kerf and low bevel
angles, which means a much cleaner cut.
Plasma cutting is not ideal for thin, detailed parts that require tight tolerances or high precision. The
kerf is much wider, and the cut edges are not as clean laser-cut edges.
Hole diameter
1. The hole diameter cut with a plasma cutter should be greater than or equal to the sheet metal
thickness. A smaller hole will result in quality issues
2. Spacing parts creatively and trying to connect them will reduce the amount of time the machine
has to start and stop resulting in a cost/piece reduction
3. Since the kerf is larger with plasma cutting, you need to account for it during design. Subtract half
the kerf size from the part’s frame and then add the other half to the inner section
4. Adding cutting nodes opposite each slot will reduce tension during cutting and lead to less
distortion
5. Utilize part nesting software to reduce waste as much as possible
6. Parts must have a smooth radius on all sharp corners. the plasma kerf will not allow for shape
corners
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Design Guidelines
Curls
Curls in sheet metal fabrication are employed to
impart strength to the edge of the sheet and
mitigate the exposure of sharp edges, enhancing
both safety and durability. Curls can be designed to
be off-center or on-center, depending on the specific
application and design requirements.
Key Design Guidelines for Curls
• Outside Radius: It should be at least double the thickness of the material to ensure structural
integrity
• Curl Opening Radius: Utilizing a radius that is twice the material thickness results in a curl opening
radius that is equal to the material thickness
• Opening Size: The opening of the curl should be at least equivalent to the thickness of the
material to maintain consistency and strength
Feature Type Minimum distance guidelines
Between a curl and a hole The curl’s radius plus the thickness of the
material
Between a curl and an internal bend ±6 times the curl’s radius plus the thickness
of the material
Between a curl and an external bend ±9 times the curl’s radius plus the thickness
of the material
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Hems
Hems are an essential element in sheet metal
design, enhancing the strength of edges and
eliminating sharpness, though they contribute
additional weight to the part.
Flat hems can lead to material fractures, so the
design should focus on open or teardrop hems to
mitigate the risk.
Key Design Guidelines for Hems
Open Hems
• Larger diameters may lose their shape
• The return flange should be at least 4x the material thickness for stability
• The inside diameter should be at minimum equal to the material thickness
Teardrop Hems
• The inside diameter should be at minimum equal to the material thickness
• Openings should at minimum be 1/4 the material thickness
• The return flange should be 4x the material thickness
Feature Type Minimum distance guidelines
Between hem and a hole ±2 x material thickness + radius of the hem
Between hem and an internal bend ±5 x material thickness
Between hem and an external bend ±8 x material thickness
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Holes and slots
In sheet metal manufacturing, the design of holes is a critical aspect that requires precision and
adherence to specific guidelines. The diameter of holes should be at least equivalent to the material’s
thickness to prevent excessive burring and ensure the longevity of the part. Proper spacing between
holes is also essential to maintain their shape during subsequent processing steps.
Key Design Guidelines for Hole Design
• Diameter Requirements: Holes and slots should have a diameter at least equal to the
• material thickness or 1.00mm (0.04”), whichever is greater. In the case of alloy or stainless steel,
the diameter should be at least twice the material thickness
• Consideration for Material Strength: For materials with higher strengths, the requirement for the
diameter of holes and slots increases to ensure structural integrity and functionality
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Notches and tabs
Notches and tabs are two approaches to get additional space in a sheet metal design to avoid
interference between features and to allow for tool access during fabrication. Notches involve the
removal of an unwanted section of sheet metal from the outer edge of the part, while tabs are
protrusions extending from the edge, often used for bending or joining purposes.
Key Design Guidelines for Notches
• Thickness of at least 1mm or equivalent to
the material thickness, depending which is
greater
• The length of a straight or radius end notch
does not exceed 5x the material thickness
• The length of V notches should be no more
than 2x its width
• The corner radius of a notch should be 0.5 x
the material thickness
Key Design Guidelines for Tabs
• Minimum width should be 3.2mm (0.126”) or two times
the material thickness, whichever is greater
• The depth of a tab should not exceed 5 times its width
Feature Type Minimum distance guidelines
Between notch and bend in a ±3x material thickness + bend radius
perpendicular plane
Between notch and bend in ±8x material thickness + bend radius
parallel plane
Between notch and hole ±1.2x material thickness
Between notches ±3.200mm (0.125”) or 2x material thickness
(whichever is greater)
±1mm (0.04”) or material thickness
Between tabs
(whichever is greater)
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Materials
Materials
Aluminum Beryllium Copper Cold-Rolled Steel
Lightweight and strong High-strength, non-magnetic Steel that has been rolled
material that is known for its alloy that contains beryllium at room temperature to
good corrosion resistance and copper. increase its strength and
and machinability. smoothness.
Pre-Plated Cold-Rolled Stainless Steel
Steel
Cold-rolled steel that has Corrosion-resistant steel
been pre-coated with a layer that contains chromium.
of metal, such as zinc or tin,
for corrosion resistance.
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Start your sheet metal project
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Head over to Get a Quote and upload your CNC ready design file with your information.
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Other UPTIVE Capabilities
• Additive Manufacturing
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• Selective Laser Sintering
• Direct Metal Laser Sintering
• Rapid Prototyping
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• CNC Machining
• Post-Processing & Finishing
Other Resources
• What is Sheet Metal Fabrication?
• Bending, Folding and Shaping: The Art of Sheet Metal Fabrication
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