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Autodesk® Inventor® 2016
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Sheet Metal Design

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Student Guide
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Revision 1.0
Cover Page

July 2015
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Authorized Author
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 ASCENT - Center for Technical Knowledge®
Autodesk® Inventor® 2016
Sheet Metal Design
Revision 1.0
Prepared and produced by:

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ASCENT Center for Technical Knowledge
630 Peter Jefferson Parkway, Suite 175

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Charlottesville, VA 22911

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866-527-2368
www.ASCENTed.com Copyright

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ASCENT - Center for Technical Knowledge is a division of Rand Worldwide, Inc., providing

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custom developed knowledge products and services for leading engineering software
applications. ASCENT is focused on specializing in the creation of education programs that
incorporate the best of classroom learning and technology-based training offerings.

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We welcome any comments you may have regarding this training guide, or any of our products.

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To contact us please email: feedback@ASCENTed.com.

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© ASCENT - Center for Technical Knowledge, 2015
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All rights reserved. No part of this guide may be reproduced in any form by any photographic,
electronic, mechanical or other means or used in any information storage and retrieval system
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without the written permission of ASCENT, a division of Rand Worldwide, Inc.
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The following are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the
USA and other countries: 123D, 3ds Max, Algor, Alias, AliasStudio, ATC, AutoCAD LT, AutoCAD, Autodesk, the Autodesk
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logo, Autodesk 123D, Autodesk Homestyler, Autodesk Inventor, Autodesk MapGuide, Autodesk Streamline, AutoLISP,
AutoSketch, AutoSnap, AutoTrack, Backburner, Backdraft, Beast, BIM 360, Burn, Buzzsaw, CADmep, CAiCE, CAMduct,
CFdesign, Civil 3D, Cleaner, Combustion, Communication Specification, Constructware, Content Explorer, Creative
Bridge, Dancing Baby (image), DesignCenter, DesignKids, DesignStudio, Discreet, DWF, DWG, DWG (design/logo),
an b

DWG Extreme, DWG TrueConvert, DWG TrueView, DWGX, DXF, Ecotect, ESTmep, Evolver, FABmep, Face Robot, FBX,
Fempro, Fire, Flame, Flare, Flint, FMDesktop, ForceEffect, FormIt, Freewheel, Fusion 360, Glue, Green Building Studio,
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Heidi, Homestyler, HumanIK, i-drop, ImageModeler, Incinerator, Inferno, InfraWorks, Instructables, Instructables (stylized
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robot design/logo), Inventor LT, Inventor, Kynapse, Kynogon, LandXplorer, Lustre, MatchMover, Maya, Maya LT,
Mechanical Desktop, MIMI, Mockup 360, Moldflow Plastics Advisers, Moldflow Plastics Insight, Moldflow, Moondust,
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MotionBuilder, Movimento, MPA (design/logo), MPA, MPI (design/logo), MPX (design/logo), MPX, Mudbox, Navisworks,
ObjectARX, ObjectDBX, Opticore, Pipeplus, Pixlr, Pixlr-o-matic, Productstream, RasterDWG, RealDWG, ReCap, Remote,
Revit LT, Revit, RiverCAD, Robot, Scaleform, Showcase, ShowMotion, Sim 360, SketchBook, Smoke, Socialcam,
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Softimage, Sparks, SteeringWheels, Stitcher, Stone, StormNET, TinkerBox, ToolClip, Topobase, Toxik, TrustedDWG,
T-Splines, ViewCube, Visual LISP, Visual, VRED, Wire, Wiretap, WiretapCentral, XSI.
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All other brand names, product names, or trademarks belong to their respective holders.
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General Disclaimer:
Notwithstanding any language to the contrary, nothing contained herein constitutes nor is intended to constitute an offer,
inducement, promise, or contract of any kind. The data contained herein is for informational purposes only and is not
represented to be error free. ASCENT, its agents and employees, expressly disclaim any liability for any damages, losses
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or other expenses arising in connection with the use of its materials or in connection with any failure of performance, error,
omission even if ASCENT, or its representatives, are advised of the possibility of such damages, losses or other
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expenses. No consequential damages can be sought against ASCENT or Rand Worldwide, Inc. for the use of these
materials by any third parties or for any direct or indirect result of that use.
The information contained herein is intended to be of general interest to you and is provided "as is", and it does not
address the circumstances of any particular individual or entity. Nothing herein constitutes professional advice, nor does
it constitute a comprehensive or complete statement of the issues discussed thereto. ASCENT does not warrant that the
document or information will be error free or will meet any particular criteria of performance or quality. In particular (but
without limitation) information may be rendered inaccurate by changes made to the subject of the materials (i.e. applicable
software). Rand Worldwide, Inc. specifically disclaims any warranty, either expressed or implied, including the warranty
of fitness for a particular purpose.
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 C o n t e n ts

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Preface ............................................................................................................ ix

In this Guide ................................................................................................... xi

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Practice Files ................................................................................................. xv

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Feedback ..................................................................................................... xvii
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Chapter 1: Introduction to Sheet Metal Modeling...................................... 1-1
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1.1 Sheet Metal Concepts..................................................................... 1-2
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Uses for Sheet Metal Components ................................................... 1-2

Similarities to Solid Models ............................................................... 1-3
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Differences from Solid Models .......................................................... 1-3

1.2 Sheet Metal Terminology................................................................ 1-4
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Sheet Metal Features........................................................................ 1-4

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Styles ................................................................................................ 1-4

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Face .................................................................................................. 1-4

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Flange ............................................................................................... 1-5

Contour Flange ................................................................................. 1-5
Lofted Flange .................................................................................... 1-6
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Contour Roll ...................................................................................... 1-6

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Hem................................................................................................... 1-6
Bend.................................................................................................. 1-7
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Bend Radius...................................................................................... 1-7

Bend Relief........................................................................................ 1-7
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Fold ................................................................................................... 1-8

Holes and Cuts.................................................................................. 1-8
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Corner Seam..................................................................................... 1-8

Rip..................................................................................................... 1-9
Unfold/Refold .................................................................................... 1-9
Flat Pattern...................................................................................... 1-10
Punch .............................................................................................. 1-10

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 Autodesk Inventor 2016 Sheet Metal Design

1.3 Sheet Metal Environment ............................................................. 1-11

Sheet Metal Tools ........................................................................... 1-11
Model Display.................................................................................. 1-11
1.4 Sheet Metal Design Process ........................................................ 1-12
Practice 1a Opening a Sheet Metal Model ......................................... 1-13

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Chapter Review Questions................................................................... 1-18

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Chapter 2: Sheet Metal Base Features ....................................................... 2-1

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2.1 Applying Existing Sheet Metal Defaults........................................ 2-2

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2.2 Creating a Face as a Base Feature................................................ 2-5

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2.3 Creating a Contour Flange as a Base Feature ............................. 2-9
2.4 Creating a Contour Roll as a Base Feature ................................ 2-13

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Practice 2a Creating Base Features I ................................................. 2-16
Practice 2b Creating Base Features II ................................................ 2-23

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e ENPractice 2c Creating Base Features III ............................................... 2-27
Practice 2d Creating Base Features IV............................................... 2-30
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Chapter Review Questions................................................................... 2-31
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Command Summary ............................................................................. 2-33

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Chapter 3: Sheet Metal Secondary Features.............................................. 3-1

3.1 Sheet Metal Parameters.................................................................. 3-2
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Parameters........................................................................................ 3-3
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3.2 Bend Relief Shapes......................................................................... 3-8

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3.3 Faces as Secondary Features...................................................... 3-10

3.4 Contour Flanges as Secondary Features ................................... 3-20
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Edge................................................................................................ 3-22
Width ............................................................................................... 3-22
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Offset............................................................................................... 3-23
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From To........................................................................................... 3-24

Distance .......................................................................................... 3-25
Width Extents for Multiple Flanges.................................................. 3-25
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3.5 Contour Rolls as Secondary Features ........................................ 3-27

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Practice 3a Creating Secondary Faces .............................................. 3-31

Practice 3b Creating Secondary Contour Flanges............................ 3-40
Practice 3c Creating Secondary Contour Rolls................................. 3-45
Chapter Review Questions................................................................... 3-48
Command Summary ............................................................................. 3-51

ii © 2015, ASCENT - Center for Technical Knowledge®

 Contents

Chapter 4: Flanges ....................................................................................... 4-1

4.1 Creating Flanges ............................................................................. 4-2
Edge Flanges .................................................................................... 4-4
Loop Flanges .................................................................................... 4-4
Distance ............................................................................................ 4-6

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To ...................................................................................................... 4-6
4.2 Corner Relief Options ................................................................... 4-14

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Corner Relief Shapes for 2 Bend Intersections............................... 4-14

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Corner Relief Size ........................................................................... 4-17
Corner Mitering ............................................................................... 4-18

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Corner Editing ................................................................................. 4-19

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Practice 4a Creating Flanges .............................................................. 4-21
Practice 4b Loop Flange...................................................................... 4-30

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Practice 4c Flanges.............................................................................. 4-36
Chapter Review Questions................................................................... 4-38

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Command Summary ............................................................................. 4-41
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Chapter 5: Bending Sheet Metal.................................................................. 5-1
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5.1 Hems ................................................................................................ 5-2
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Single Hem........................................................................................ 5-4

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Teardrop Hem ................................................................................... 5-4

Rolled Hem ....................................................................................... 5-5
Double Hem ...................................................................................... 5-6
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Edge.................................................................................................. 5-7
Width ................................................................................................. 5-7
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Offset................................................................................................. 5-8
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From To............................................................................................. 5-8

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5.2 Folds................................................................................................. 5-9

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5.3 Bends ............................................................................................. 5-15

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Practice 5a Hems, Folds, and Bends.................................................. 5-19

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Practice 5b Bending Sheet Metal........................................................ 5-27

Practice 5c Bracket .............................................................................. 5-35
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Practice 5d Working in an Assembly ................................................. 5-39

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Chapter Review Questions................................................................... 5-44

Command Summary ............................................................................. 5-47

Chapter 6: Corner Rounds and Chamfers.................................................. 6-1

6.1 Creating Corner Rounds ................................................................ 6-2
6.2 Creating Corner Chamfers ............................................................. 6-6
Practice 6a Corner Rounds and Chamfers I ...................................... 6-10

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 Autodesk Inventor 2016 Sheet Metal Design

Practice 6b Corner Rounds and Chamfers II ..................................... 6-15

Practice 6c Corner Rounds and Chamfers III .................................... 6-17
Chapter Review Questions................................................................... 6-20
Command Summary ............................................................................. 6-22

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Chapter 7: Sheet Metal Cuts ........................................................................ 7-1

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7.1 Creating Cut Features..................................................................... 7-2
Distance ............................................................................................ 7-6

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To Next.............................................................................................. 7-6

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To ...................................................................................................... 7-7

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From To............................................................................................. 7-7
All ...................................................................................................... 7-8
7.2 Creating Straight Holes ................................................................ 7-11

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Linear Placement ............................................................................ 7-12

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Concentric Placement ..................................................................... 7-13
From Sketch Placement.................................................................. 7-13

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On Point Placement ........................................................................ 7-14
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Clearance Hole ............................................................................... 7-16
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7.3 Using Punch Tool Features.......................................................... 7-18
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Preview ........................................................................................... 7-20

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Geometry ........................................................................................ 7-21

Size ................................................................................................. 7-22
7.4 Creating a Punch Tool .................................................................. 7-24
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Placement Help............................................................................... 7-27

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7.5 Cuts Using Surfaces ..................................................................... 7-28

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Practice 7a Creating Cut Features I.................................................... 7-31

Practice 7b Creating Cut Features II................................................... 7-35
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Practice 7c Punch Tool, Holes, and Cut Features............................. 7-38

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Practice 7d Create and Insert a Punch Feature................................. 7-50

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Chapter Review Questions................................................................... 7-55

Command Summary ............................................................................. 7-58
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Chapter 8: Corner Seams............................................................................. 8-1

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8.1 Creating Corner Seams and Miters ............................................... 8-2

Overlap Options ................................................................................ 8-2
Overlap Options for Seams Between Intersecting Faces ................. 8-6
Overlap Options for Miters between Coplanar Faces ..................... 8-10
8.2 Creating Corner Rips .................................................................... 8-16
8.3 Converting Corner Seams and Bends ........................................ 8-17

iv © 2015, ASCENT - Center for Technical Knowledge®

 Contents

Practice 8a Corner Seams and Miters I .............................................. 8-21

Practice 8b Corner Seams and Miters II............................................. 8-25
Chapter Review Questions................................................................... 8-33
Command Summary ............................................................................. 8-35

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Chapter 9: Flat Pattern Environment .......................................................... 9-1

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9.1 Creating Flat Patterns..................................................................... 9-2
A-Side Definition ............................................................................... 9-4

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Switching Between the Folded and Flat Environments..................... 9-6

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Unfolding the Flat Pattern ................................................................. 9-6

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Unfolding Parts Without a Planar Face ............................................. 9-7
Overlapping Features in Flat Pattern ................................................ 9-7
9.2 Orienting Flat Patterns ................................................................... 9-9

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9.3 Punch Representations ................................................................ 9-15
Punches Through a Feature ........................................................... 9-15

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Embossed Features ........................................................................ 9-17
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9.4 Bend Angle .................................................................................... 9-19
9.5 Flat Pattern Cleanup ..................................................................... 9-20
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Adding Features to a Flat Pattern ................................................... 9-20
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Copy to Flat Pattern ........................................................................ 9-21

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Flat Pattern Features Panel ............................................................ 9-21

General Steps ................................................................................. 9-22
9.6 Exporting to DXF/DWG ................................................................. 9-26
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Exporting Flat Patterns.................................................................... 9-26

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Exporting Faces .............................................................................. 9-30

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Practice 9a Flat Pattern I...................................................................... 9-33

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Practice 9b Flat Pattern II .................................................................... 9-40

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Practice 9c Flat Pattern of Curved Parts............................................ 9-46

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Chapter Review Questions................................................................... 9-48

Command Summary ............................................................................. 9-51
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Chapter 10: Lofted Flange and Rips ......................................................... 10-1

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10.1 Lofted Flange................................................................................. 10-2

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10.2 Rip .................................................................................................. 10-7

Practice 10a Lofted Flanges and Rips................................................ 10-9
Practice 10b Point to Point Rip ......................................................... 10-20
Chapter Review Questions................................................................. 10-22
Command Summary ........................................................................... 10-24

© 2015, ASCENT - Center for Technical Knowledge® v

 Autodesk Inventor 2016 Sheet Metal Design

Chapter 11: Unfold and Refold .................................................................. 11-1

11.1 Unfold and Refold ......................................................................... 11-2
Practice 11a Unfold/Refold.................................................................. 11-6
Chapter Review Questions................................................................. 11-10

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Command Summary ........................................................................... 11-12

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Chapter 12: Multi-Body Sheet Metal Modeling......................................... 12-1

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12.1 Multi-Body Modeling ..................................................................... 12-2
Creating the First Solid Body .......................................................... 12-3

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Creating Additional Solid Bodies..................................................... 12-4

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Assigning Features to Solid Bodies ................................................ 12-4
Manipulating Solid Bodies............................................................... 12-4
Solid Body Display ........................................................................ 12-11

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Solid Body Properties.................................................................... 12-11

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Practice 12a Multi-Body Sheet Metal Modeling ............................... 12-12

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Chapter Review Questions................................................................. 12-26
e ENCommand Summary ........................................................................... 12-28
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Chapter 13: Documentation and Annotation ........................................... 13-1
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13.1 Sheet Metal Drawing Terminology .............................................. 13-2

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13.2 Creating Sheet Metal Drawings ................................................... 13-3

As-Built Drawings............................................................................ 13-3
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Flat Pattern Views ........................................................................... 13-4

Component Tab .............................................................................. 13-5
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Model State Tab.............................................................................. 13-7

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13.3 Bend & Punch Notes..................................................................... 13-9

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13.4 Bend Tables................................................................................. 13-11

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Source Options ............................................................................. 13-12

Columns and Rows ....................................................................... 13-13
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13.5 Punch Tables............................................................................... 13-15

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13.6 Bend Order .................................................................................. 13-19

Directed Reorder........................................................................... 13-19
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Sequential Reorder ....................................................................... 13-19

Individual Override ........................................................................ 13-20
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13.7 Cosmetic Centerlines ................................................................. 13-21

Practice 13a Sheet Metal Documentation I ...................................... 13-23
Practice 13b Sheet Metal Documentation II ..................................... 13-31
Practice 13c Bend Order.................................................................... 13-40
Chapter Review Questions................................................................. 13-42
Command Summary ........................................................................... 13-45

vi © 2015, ASCENT - Center for Technical Knowledge®

 Contents

Chapter 14: Converting Parts to Sheet Metal........................................... 14-1

14.1 Converting Solid Models to Sheet Metal..................................... 14-2
Common Shapes to Convert to Sheet Metal................................... 14-2
14.2 Non-Ruled Surfaces.................................................................... 14-14

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Practice 14a Convert to Sheet Metal ................................................ 14-16
Practice 14b Import IGES File ........................................................... 14-24

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Practice 14c Solid Model to Sheet Metal.......................................... 14-26

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Chapter Review Questions................................................................. 14-32

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Command Summary ........................................................................... 14-34

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Appendix A: Sheet Metal Rules...................................................................A-1
A.1 Working with Sheet Metal Rules....................................................A-2

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Rule List ............................................................................................ A-3
Setting the Active Rule...................................................................... A-3

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Modifying Existing Rules ................................................................... A-4
e EN Creating a New Sheet Metal Rules ................................................... A-4
Deleting Sheet Metal Rules............................................................... A-4
A.2 Sheet, Bend, and Corner Tab Options ..........................................A-5
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Sheet Tab.......................................................................................... A-5
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Bend Tab......................................................................................... A-11

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Corner Tab ...................................................................................... A-18

Corner Relief Size ........................................................................... A-21
3 Bend Intersections ....................................................................... A-22
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A.3 Bend Tables...................................................................................A-25

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Bend Table Format ......................................................................... A-27

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Bend Table Information................................................................... A-27

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Practice A1 Sheet Metal Styles ........................................................... A-28

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Practice A2 Bend Relief Options and Unfold Options ...................... A-34

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Practice A3 Attaching a Bend Table................................................... A-39

Chapter Review Questions...................................................................A-44
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Command Summary .............................................................................A-46

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Appendix B: Additional Practices ...............................................................B-1

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Practice B1 Create Parts........................................................................ B-2

Appendix C: Autodesk Inventor 2015 Certification Exam Objectives .....C-1

Index ...................................................................................................... Index-1

© 2015, ASCENT - Center for Technical Knowledge® vii

 Autodesk Inventor 2016 Sheet Metal Design

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viii © 2015, ASCENT - Center for Technical Knowledge®

 Preface

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The Autodesk® Inventor® 2016 Sheet Metal Design training guide introduces the
concepts and techniques of sheet metal modeling with the Autodesk Inventor
software.

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The structure of the training guide follows the typical stages of using the Autodesk
Inventor software. That is, to create and edit sheet metal parts, generate flat

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patterns, and document the designs in drawings.
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Topics Covered
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• Autodesk Inventor Sheet Metal interface
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• Sheet metal design process

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• Creating base Faces, Contour Flanges, and Contour Rolls

• Creating secondary Faces, Contour Flanges, and Contour Rolls
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• Sheet metal parameters

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• Creating Flanges
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• Creating Hems, Folds, and Bends

• Corner Rounds and Chamfers
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• Sheet Metal Cuts (Holes, Cuts, and Punch Features)

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• Corner Seams (Seams and Miters)

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• Generating Flat Patterns

• Lofted Flanges
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• Rips
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• Unfolding and Refolding

• Multi-Body Sheet Metal Modeling
• Documentation and Annotation of drawings
• Converting solid models to sheet metal models
• Sheet Metal Styles

© 2015, ASCENT - Center for Technical Knowledge® ix

 Autodesk Inventor 2016 Sheet Metal Design

Note on Software Setup

This training guide assumes a standard installation of the software using the
default preferences during installation. Lectures and practices use the standard
software templates and default options for the Content Libraries.

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Students and Educators can Access Free Autodesk Software and

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Resources

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Autodesk challenges you to get started with free educational licenses for

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professional software and creativity apps used by millions of architects,

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engineers, designers, and hobbyists today. Bring Autodesk software into your
classroom, studio, or workshop to learn, teach, and explore real-world design
challenges the way professionals do.

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Get started today - register at the Autodesk Education Community and download
one of the many Autodesk software applications available.

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Visit www.autodesk.com/joinedu/

Note: Free products are subject to the terms and conditions of the end-user
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license and services agreement that accompanies the software. The software is
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for personal use for education purposes and is not intended for classroom or lab
use.
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x © 2015, ASCENT - Center for Technical Knowledge®

 In th is Gu id e

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The following images highlight some of the features that can be found in this
Training Guide.

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The Practice Files page tells
you how to download and install
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the practice files that are

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provided with this training guide.

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FTP link for practice files

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Chapters
Each chapter begins with a brief
introduction and a list of the
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chapter’s Learning Objectives.

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Learning Objectives for

the chapter

© 2015, ASCENT - Center for Technical Knowledge® xi

 Autodesk Inventor 2016 Sheet Metal Design

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Instructional Content
Each chapter is split into a
series of sections of

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instructional content on specific

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topics. These lectures include
the descriptions, step-by-step

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Side notes procedures, figures, hints, and
Side notes are hints or information you need to achieve

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additional information for the chapter's Learning
the current topic. Objectives.

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Practice Objectives
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Practices
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Practices enable you to use the

software to perform a hands-on
review of a topic.
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Some practices require you to

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use prepared practice files,

which can be downloaded from
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the link found on the Practice

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Files page.
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Chapter Review Questions

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Chapter review questions,

located at the end of each
chapter, enable you to review
the key concepts and learning
objectives of the chapter.

xii © 2015, ASCENT - Center for Technical Knowledge®

 In this Guide

Command Summary
The Command Summary is

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located at the end of each
chapter. It contains a list of the
software commands that are

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used throughout the chapter,

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and provides information on
where the command is found in

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the software.

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e EN Autodesk Certification Exam
Appendix
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This appendix includes a list of
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the topics and objectives for the

Autodesk Certification exams,
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and the chapter and section in

which the relevant content can
be found.
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Icons in this Training Guide

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The following icons are used to help you quickly and easily find helpful
information.
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Indicates items that are new in the Autodesk Inventor 2016 software.
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Indicates items that have been enhanced in the Autodesk Inventor 2016
software.

© 2015, ASCENT - Center for Technical Knowledge® xiii

 Autodesk Inventor 2016 Sheet Metal Design

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xiv © 2015, ASCENT - Center for Technical Knowledge®

 Chapter

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Introduction to Sheet Metal

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Modeling

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The Autodesk® Inventor® sheet metal environment enables you to create features
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that are specific to the sheet metal modeling process. This chapter introduces you
to some of the tools and terminology that are used to create these types of parts
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and are covered throughout this training guide.

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Learning Objectives in this Chapter

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• Identify the differences between solid and sheet metal models.

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• Gain an understanding of the sheet metal terminology that is used in this training guide.
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• Recognize the Sheet Metal interface that is used to create and work in a sheet metal model.
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• Understand the overall workflow that is used to create a sheet metal model in the Autodesk
Inventor software.
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• Start the creation of a new sheet metal model using a provided template.
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© 2015, ASCENT - Center for Technical Knowledge® 1–1

 Autodesk Inventor 2016 Sheet Metal Design

1.1 Sheet Metal Concepts

Uses for The sheet metal application in the Autodesk Inventor software
enables you to effectively capture design intent while creating

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Sheet Metal sheet metal parts within the sheet metal environment. An
Components example is shown in Figure 1–1.

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Figure 1–1
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The Autodesk Inventor Sheet Metal environment enables you to
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do the following:
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• Create features specific to the sheet metal manufacturing

process.
an b

• Design a sheet metal model within the context of an

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assembly so that all 3D information is present.

ng e
yi vid

• Create different instances of the model to use at different

times or for varied situations.
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• Extract information and establish dimensional and geometric

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controls that are beneficial to the manufacturing process.

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• Generate views and information to document the design of

sheet metal parts.
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 Introduction to Sheet Metal Modeling

Similarities to The creation of a sheet metal model is similar to the creation of a

solid part in the following ways:
Solid Models
Considering the order in • Sheet metal models are feature-based.
which the part is bent or

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cut during fabrication is • Sheet metal parts can include sketched and placed features.
equally important to

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considering the design • Individual sheet metal features (e.g., faces, flanges, bends,
cuts, and holes) are created in sequence and reference one

id w
intent in sheet metal.
another, resulting in parent-child feature relationships.

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• Reference geometry can be created when adding certain

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types of features, such as flanges or holes, just as extrusions
and cuts can reference other features on solid parts.

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• Sheet metal parts can use named parameters and equations.

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• A sheet metal model can be designed using multi-body
e EN modeling.

Differences The creation of a sheet metal model is different from the creation
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of a solid part in the following ways:
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from Solid
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• Sheet metal parts have a constant thickness.

Models
• Radii and bend relief sizes are generally consistent within a
an b

part.
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• Flat patterns can be created for manufacturing drawings.

ng e
yi vid

• Features can be added to a flat pattern but do not display on

the model in the folded state.
op ro

Several simple sheet metal parts are shown in Figure 1–2.

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Figure 1–2

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 Autodesk Inventor 2016 Sheet Metal Design

1.2 Sheet Metal Terminology

It is helpful to become familiar with some of the standard
terminology used in sheet metal design. Figure 1–3 shows a part
with a few of the features labeled.

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Cut

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Face

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Flange

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Bend Hole

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Figure 1–3
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Sheet Metal Various sheet metal features can be produced (such as a hems,
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flanges, cut-outs, holes, and punches).

Features
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Styles Sheet metal styles include settings, such as material thickness,

default bend radius, and type of bend relief for a part. Most of the
style information is stored in standard parameters.
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Face A sheet metal Face feature is a flat area of the sheet metal
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model. It is created from a closed loop sketch profile with

thickness added. Its final shape is controlled by the shape of the
closed sketch and other features that are attached to (or
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removed from) it.

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The Face command creates planar (flat) sheet metal features,

which are often the building blocks for sheet metal parts. Faces
can have a simple rectangular profile, as shown on the left in
Figure 1–4, or a more complex profile as shown on the right.

1–4 © 2015, ASCENT - Center for Technical Knowledge®

 Introduction to Sheet Metal Modeling

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Figure 1–4

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Flange A standard Flange feature is a type of secondary planar feature

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added to a sheet metal part. When you create a flange, a Bend
feature is also created between the flange and the face feature
on which the flange is built. A flange can be added to a single

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edge of a face or to an edge loop on a face. Figure 1–5 shows a

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face with two flanges added.

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Figure 1–5
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Contour Flange A Contour Flange feature is a feature created from an open loop
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sketched profile. The profile is extruded to create a surface and

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then adds thickness to turn it into a sheet metal feature. Contour

flanges can be used as base features or secondary features.
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They are often used to create a rolled feature or multiple flanges

on a sheet metal part.
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A part made from an open loop sketch is shown on the left in

Figure 1–6. It is turned into a contour flange as shown on the
right.
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Open loop
sketch

Figure 1–6

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 Autodesk Inventor 2016 Sheet Metal Design

Lofted Flange A Lofted Flange feature creates transitional sheet metal

geometry that is blended between two profile sketches, as
shown in Figure 1–7. Lofted flanges can be used as base or
secondary features.

Lofted flanges are most

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Sketched Lofted
commonly used with sections flange
duct design.

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Figure 1–7

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Contour Roll A Contour Roll feature creates sheet metal geometry that
e EN supports the roll forming sheet metal manufacturing process.
Similar to contour flanges, a contour roll feature requires an open
loop sketch profile that is revolved to create the required
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geometry, as shown in Figure 1–8. Contour rolls can be used as
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base or secondary features.

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Contour
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roll
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Sketched
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entities
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Figure 1–8
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Hem Adding a Hem feature creates a folded edge along sheet metal
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edges to strengthen the part, and/or to eliminate sharp edges.

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Four standard hem styles are shown in Figure 1–9.

Single Double Rolled Teardrop

Figure 1–9

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 Introduction to Sheet Metal Modeling

Bend You can add a Bend feature between two sheet metal faces that
are parallel or at an angle to each other. A bend is a feature that
is dependent on two existing faces. It alters the length of a face,
if necessary, so that the two faces can meet at the bend, as
shown in Figure 1–10.

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Face2 Face 2 extended to

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added bend feature

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Face 1

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Figure 1–10

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Bend Radius Bend features can be added between existing features or

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incorporated during the creation of a feature. They are added to
e EN accommodate the fabrication of the sheet metal part when it is
formed from a flat sheet to create a folded shape. If an
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appropriate radius is not used, the part can split along a sharp
corner. In general, the radius used for a bend is determined by
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the type and thickness of the material. However, a zero bend

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radius can also be applied, as required. Bend radius values can

be assigned to the model using the Sheet Metal Rule or entered
individually as you create features.
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Bend Relief
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Bend Relief features are defined to enable bends to be

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fabricated. In some cases, they remove material to enable

clearance between edges. Figure 1–11 shows straight, round,
and tear style bend reliefs applied on the three flanges from left
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to right.
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Figure 1–11

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 Autodesk Inventor 2016 Sheet Metal Design

Fold A Fold bends a sheet metal face by folding it along a sketched

line. The sketched line must terminate at the edges of the face,
as shown in Figure 1–12. The fold becomes a dependent feature
on the face.

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Sketch line
for fold

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Fold feature

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Figure 1–12

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Holes and Cuts Hole and Cut features remove material, similar to the methods

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used in solid models, as shown in Figure 1–13. Cuts require a
closed loop sketch to define the profile of the cut.

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e EN
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d
ng e
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Figure 1–13
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Corner Seam Corner Seam features create an overlap or gap at the

intersection of two or three faces. Examples with a gap and
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overlap are shown in Figure 1–14.

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Corner seam Corner seam

with gap with overlap
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between faces between faces

Figure 1–14

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 Introduction to Sheet Metal Modeling

Rip A Rip feature enables you to create an open gap (rip) in

geometry that is closed, similar to that shown in Figure 1–15.
Adding a rip to a closed shape enables you to generate a flat
pattern. Rips are not affected by cut-outs, emboss, or other
formed features.

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Rip

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Figure 1–15

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Unfold/Refold The Unfold and Refold features enable you to unfold a model at
any point in the its design, and then refold the geometry at any
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point thereafter, as shown in Figure 1–16. Any features created
between the unfolding and refolding are maintained on the
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model geometry as it was created when unfolded.

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Unfold Refold
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Figure 1–16
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 Autodesk Inventor 2016 Sheet Metal Design

Flat Pattern Flat Pattern features are used to provide information about a part
before bending and other manufacturing processes as shown in
Figure 1–17.

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Figure 1–17

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Punch When modeling sheet metal components, you might place the
same feature(s) multiple times for use in the same part or
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different parts. The Punch Tool command enables you to place
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a saved feature or group of features in one command, as shown

in Figure 1–18. Common uses for punch tools include keyways,
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slots, and cuts for specific shape connectors. When placing a

Punch feature in a model, you can control the placement and
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size of the feature based on the definition of the Punch.

d
ng e
yi vid
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Figure 1–18
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 Introduction to Sheet Metal Modeling

1.3 Sheet Metal Environment

Autodesk Inventor sheet metal tools are specifically designed for
creating sheet metal parts. Figure 1–19 shows the user interface
with the Sheet Metal tab active. After creating a sketch for your

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base feature, you can add faces, contour flanges, cuts, folds,
and other features.

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Figure 1–19
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Sheet Metal The Sheet Metal tab (shown in Figure 1–20) provides access to
the available tools that you can use to design sheet metal
Tools
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models.
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m

Figure 1–20
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The sheet metal application includes several tools that should be

familiar from working with solid parts (e.g., Hole, Work Plane,
and Pattern). Also included are tools specific to sheet metal
fabrication (e,g.,Face, Flange, Fold, and Corner Seam).

Model Display As with solid models, you can display sheet metal models in
shaded, hidden edges displayed, or wireframe display. You also
have access to the same model orientation tools as when
orienting a solid model.

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 Autodesk Inventor 2016 Sheet Metal Design

1.4 Sheet Metal Design Process

The process of creating sheet metal models is similar to the
process of creating solid part models. Individual features are
created in sequence and reference one another, resulting in

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parent-child relationships.

When modeling a sheet To start a new sheet metal part, use of the following methods:

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metal part, remember

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that the part always has
• On the Get Started tab>Launch panel, click (New).

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a consistent wall
thickness.

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• Click (New) in the Quick Access Toolbar.

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• Expand (Application Menu) and select New.

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When you use any of these three methods, the Create New File
e EN dialog box opens, which enables you to select a template to use
as the basis for a new sheet metal model. Select a sheet metal
template from those available in the English and Metric folders.
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Hint: Starting a Sheet Metal Model from the My Home tab.

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You can start a new sheet metal model on the My Home tab by
selecting the Advanced option in the New area and selecting
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a sheet metal template for use. There is no button in the New

area to quickly create a new sheet metal model with the
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default template.
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Use the following steps as the general workflow for creating new
sheet metal models:
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1. Start a new part using a sheet metal template (.IPT) file.

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You can also convert a 2. Define the sheet metal style parameters, as required.
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solid part into a sheet 3. Create the base feature.

metal part by clicking 4. Add secondary features (such as flanges, hems, and
cut-outs).
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(Convert to 5. Create the flat pattern, if needed.

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Sheetmetal) in the 6. Create the deliverables (drawings).

Model tab>Convert
panel.

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 Introduction to Sheet Metal Modeling

Practice 1a Opening a Sheet Metal Model

Practice Objectives
• Assign a project file for use in the Autodesk Inventor software.

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• Open existing sheet metal models and review their features and the
relationships between features using the Model browser.

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• Manipulate the visual display style and orientation of the sheet metal
model.

id w
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In this practice, you will use the sheet metal environment and

fo rev
tools to identify sheet metal features and manipulate the model’s
display.

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Task 1 - Set up a Project folder.

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1. In the Get Started tab>Launch panel, click (Projects) to

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open the Projects dialog box. Project files identify folders that
e EN contain the required Autodesk Inventor models.
2. Click Browse and find and select C:\Autodesk Inventor
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This project file is used 2016 Sheet Metal Practice Files\Sheet Metal.ipj (or the
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for the entire training directory of the installation files if you changed the default
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guide. directory). Click Open. The Projects dialog box updates and
a checkmark displays next to the new project name,
indicating that it is the active project. The project file tells the
an b

system where your files are stored. As an alternative, you can

d

select Browse from the Project drop-down list on the My

ng e

Home dashboard and find and select the project file.

yi vid

3. Click Done.
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Task 2 - Open a sheet metal model.

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1. Open sm_door_bell_base.ipt. The part displays as shown

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in Figure 1–21. The End of Folded icon is placed just below

Flange1.
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Figure 1–21

© 2015, ASCENT - Center for Technical Knowledge® 1–13

 Autodesk Inventor 2016 Sheet Metal Design

Task 3 - Identify sheet metal features in the Model browser.

1. Drag the End of Folded icon through the individual features

in the Model browser, stopping under each feature to see
how the sheet metal part was created (you might need to

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rotate the model to display the features).

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2. When the End of Folded icon is at the bottom of all of the
features, the part displays a variety of bends, folds, cuts, and

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faces, as shown in Figure 1–22.

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d
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Figure 1–22
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3. Expand Face1 in the Model browser and select the sketch to

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display its sketch dimensions.

4. Expand each of the four Flange features and note that each
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one has a Bend feature as a dependent (child) feature.

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5. Hover the cursor over Face5 in the Model browser and note
that the corresponding feature highlights in the model.

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 Introduction to Sheet Metal Modeling

Task 4 - Identify parent-child feature relationships.

1. Right-click on Flange2 in the Model browser and select

Suppress Features. Click Accept in the Warning dialog box.
Bend2 is automatically suppressed because it is a child

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feature of Flange2.

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2. Unsuppress Flange2.

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3. Suppress Bend9 in the Model browser. Click Accept in the
Warning dialog box. The part is still displayed but the bend

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feature between Face4 and Cut3 is suppressed.

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4. Unsuppress Bend9.

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Task 5 - Manipulate the model’s display style and

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orientation.

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e EN 1. Use the viewing tools to spin the model to the approximate
position shown in Figure 1–23. Zoom in to the area shown in
Figure 1–23.
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Orient the model and

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zoom in on this area

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d
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Figure 1–23
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 Autodesk Inventor 2016 Sheet Metal Design

2. Select the View tab. Using the Visual Style drop-down list in
the Appearance panel, change the display to Shaded with
Hidden Edges and Wireframe. The wireframe model is
shown in Figure 1–24.

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Figure 1–24
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The Fixed Distance 3. Move your cursor over the ViewCube, right-click on
option enables you to
(Home) in the top-left corner of the ViewCube and select
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store the zoom level of
Set Current View as Home>Fixed Distance. This sets the
the view. The Fit to
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rotated view as the isometric home view for the model.

View option maintains
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the orientation and 4. Practice using the ViewCube to orient the model by selecting
always refits the view in the sides of the ViewCube or its corners. You can also rotate
the main window.
an b

the model by selecting the clockwise or counter-clockwise

arrows that display when your cursor is positioned over the
d

ViewCube.
ng e
yi vid

5. Move your cursor over the ViewCube and click (Home) in

the top-left corner of the ViewCube to orient the model into its
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isometric Home view (3D). You can also right-click on the

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ViewCube and select Go Home to orient the model in the

same way.
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6. Save and close the file.

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 Introduction to Sheet Metal Modeling

Task 6 - Review a second simple model.

1. Open sm_endplate.ipt as shown in Figure 1–25. Review the

features in the Model browser.

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Figure 1–25
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2. Rotate the part. Change the view to Wireframe.

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3. Close the part without saving.

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 Autodesk Inventor 2016 Sheet Metal Design

Chapter Review Questions

1. Which of the following describes valid methods for creating a
sheet metal part? (Select all that apply.)

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a. Convert an existing solid model to sheet metal.

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b. Start a new part using a standard part.ipt template file and
assign all of the sheet metal parameters in the

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Parameters dialog box.

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c. Start a new part using a sheet metal.ipt template file.

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2. Which of the following statements is true regarding a sheet
metal model? (Select all that apply.)

tly r
a. Sheet metal parts can include sketches and placed

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features to create its geometry.

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b. Unlike solid part models, parent-child relationships are not
e EN established between the features in a sheet metal model.
c. Unlike solid part models, sheet metal models have a
constant thickness.
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d. The model display and orientation settings for a sheet

metal model are the same as those available in a solid
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part model.
3. Which of the following are valid sheet metal features? (Select
an b

all that apply.)

d

a. Extrude
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b. Face
c. Contour Flange
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d. Bend
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e. Rip
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f. Tear
g. Hole
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 Introduction to Sheet Metal Modeling

4. Which sheet metal feature was used to create the geometry

shown in Figure 1–26?

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Figure 1–26
a. Face

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b. Flange
c. Contour Flange

st T
e EN d. Lofted Flange
5. Which sheet metal feature was used to create the geometry
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shown in Figure 1–27?
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d
ng e
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Figure 1–27
a. Face
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b. Flange
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c. Contour Flange
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d. Contour Roll

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 Autodesk Inventor 2016 Sheet Metal Design

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d
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1–20 © 2015, ASCENT - Center for Technical Knowledge®