Sheet Metal Design Guidelines

Sharing is caring

6 6
Shares

Sheet metal design guidelines are followed to design quality sheet metal enclosures. This
helps in delivering the product at low cost and time. All design guidelines can not be
followed in one part. Therefore exceptions can be there for complex features design. In this
article we will discuss sheet metal design guidelines for manufacturing parts using sheet
metal press bending.

Sheetmetal are available in standard thickness. Manufacturer provide sheets thickness in

gauge. But designers design sheet metal parts considering sheet thickness in mm. You can
use this guide to convert sheet thickness from gauge to mm.

Sheet Metal Material Selection

Material selection is a very important part of product design. It also a ects the sheet metal
enclosure design. Sheet thickness and material can be selected using:

Simulation Studies
Past Experience
Study existing products
Experimental Studies

You can also use this guide to know more about sheet metal material selection.

Inside Bend Radius

Sharp inside bend radius are not recommended in sheet metal design. Because they can
cause material ow problems in soft material and fracturing in hard material. Which results
in localized necking or fracture.

Recommended inside bend radius for sheet metal parts should be equal to material
thickness. But for harder materials ( e.g. CRCA) inside bend radius equal to 0.65 times of
sheet thickness is also enough.

Bend radius throughout the sheet metal design is kept constant to take the advantage of
using the same tool during manufacturing.

Ad
Steel Hand Stamp
Manufacturer - Steel Letter,…
AdTaiwan Made. High Quality, OEM &
ODM Metal Hand Stamps,…
youngcycle.com.tw

Learn more

Minimum Bend/Flange Length Guidelines

Minimum sheet metal ange bend length is maintained to avoid cracks in the bending
area. It shall be equal to three times of sheet thickness plus bend radius.

Min. ange Bend length = 3X Sheet Thickness + Bend Radius

Minimum Hole Diameter Guidelines

Small sized punch are more prone to failure during punching operation. Therefore for
softer materials, the recommended minimum hole diameter is equal to sheet
thickness. Whereas for harder materials recommended minimum hole diameter is
thickness. Whereas for harder materials recommended minimum hole diameter is
equal to two times of sheet thickness.

Hole/Slot Distance from Bend Edge

Minimum distance between hole/slot edge to bend edge is maintained to avoid metal
distortion, deformation and fracturing.

Recommended minimum distance between hole /slot edge to bend in sheet metal
design is three times the sheet thickness plus bend radius.

Ad
Pipe making machine -
stainless steel
Ad6-325mm online forming. nominated
supplier of ss tube mills
gdseko.com

Learn more

Center to Center Distance Between Two Holes

Minimum center to center hole distance is maintained to avoid metal distortion,
deformation and fracturing.

Minimum distance between two hole centers during sheet metal design should be equal
to sum of hole radius plus two times the sheet thickness.

Recommended Distance = Radius of Hole1 + Radius of Hole2 + Sheet Thickness

E ect Of Grain Direction in Sheet Metal Bending

 During sheet metal processing ( rolling operation), material grains are arranged in the
direction of rolling.

When Sheetmetal is bend perpendicular to rolling direction grain rearranges. That has
negligible e ect on part strength. 

Whereas bending parallel to rolling direction can lead to cracks because of destruction
in grain structure.

Bend Relief

We use cookies to ensure that we give you the best experience on our website. If you continue to use this site we will
assume that you are happy with it.

Ok Pr ivacy policy
 Bend relief is provided at the end of bending edge in sheet metal design to avoid any
crack tearing in the corner.

Relief height is generally kept greater than two times of sheet thickness plus bend radius.

Ad
Steel Hand Stamp
Manufacturer - Steel Letter,…
Ad Taiwan Made. High Quality, OEM &
ODM Metal Hand Stamps,…
youngcycle.com.tw

Learn more

Extrude Hole Size & Position Guidelines

Creating an extruded hole using a punching process requires extreme pressure/Force.

Extruded holes very close to the part edge can lead to sheet metal deformation or tearing.
Therefore the minimum distance between the extruded hole to edge if maintained.
 Extruded hole to part edge (B)  = 3T + D/2

Center of extruded Holes (A) =  (5 + Hole Dia + 2T)

Extruded Hole and bend edge (C) = 3T + R + D/2

Round Emboss Design Guidelines

Creating Emboss feature using sheet metal punching requires extreme pressure. Very
close emboss to the part edge, can lead to deformation in the sheet metal part.

A – Distance From Emboss To part Edge = 3T + D/2

B- Distance Between Two Emboss =  (5 + D)

C- Distance between Emboss and Sheet Metal bend = 3T + R + D/2

Dimple Feature Design Guidelines

Louver Feature Design Guide

Minimum distance between louver feature and bending edge is maintained to avoid metal
Minimum distance between louver feature and bending edge is maintained to avoid metal
deformation.

(P1) Distance Between Two lowers on Shorter Edge = 5 mm

(P2) Distance Between Two lowers on Longer Edge = 8 mm

Round Knockout Design Recommendation

Minimum distance between knockout feature and bending edge is maintained to avoid
metal deformation.

(P1) Distance Between Two knockout  = (5 + D) mm

Conclusion

To sum up,  sheet metal design guidelines are followed to ensure good quality, reduced
cost and robust design. All design guidelines can not be followed in one part. Therefore
exceptions can be there for complex features design. We suggest you read this article on
electronics enclosure design. This will give you an overview of the complete enclosure
design process.

Got Questions?  We will be happy to help.

If you think we missed Something?  You can add to this article by sending a message in the

comment box. We will do our best to add it in this post.

 K Factor and Sheet Metal Flat Pattern Calculations

Sheet Metal Electronics Enclosure Design Guidelines

Sharing is caring

6 6
Shares

Mini injection Sheet Metal Armor Plastics - Sheet Metal K-

molding machine Design Parameter Polycarbonate Factor Bend
- Desktop Calculator Sheets Allowance and…
Ad haijiamc.com smlease.com Ad armorplastics.com smlease.com

silicone injection Di erence K-factor How to Join Sheet

mold - LSR mold Between Calculator for Metal Parts :
manufactuer Blanking,… Sheet Metal… Sheet Metal…
Ad tymsilicone.com smlease.com smlease.com smlease.com

Related Posts
Sheetmetal Sheet Metal K- Sheet Metal Di erence
Design Interview Factor Bend Enclosure Design Between
Questions and Allowance and For Electrical and Blanking,
Answers Flat Length Electronics Punching &
Products Piercing in Sheet
This article covers K-Factor in sheet Metal
commonly asked metal bending is a Electronics and
sheetmetal design constant. It is… electrical industries In sheet metal, this
interview questions use sheet metal
and… enclosures to question always
enclose… creates some
confusion. What…