Sheetmetal Design Using Creo 5.0

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SHEETMETAL DESIGN USING CREO 5.0
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Overview
 In this course, you will learn how to create sheetmetal parts in Creo Parametric. The course builds upon
the basic lessons you learned in Introduction to Creo Parametric 5.0 and serves as the second stage of
learning. In this course, you will learn how to design sheetmetal parts and assemblies, including sheetmetal
production drawings. All the functions needed to create sheetmetal parts, drawings, and assemblies are
covered. Upon completion of this course, you will be able to create sheetmetal design models, create the flat
state of the model, and document both in production drawings.
 This course has been developed using Creo Parametric 5.0 F000.
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Course Objectives
 Create, convert, and display the sheetmetal model

 Use methods of developed length calculation
 Use primary and secondary wall features, as well as partial walls
 Use bend relief
 Use unbend and bend-back features
 Apply sheetmetal bend features
 Use flat patterns
 Create sheetmetal cuts
 Create forms
 Use notch and punch features
 Utilize the sheetmetal environment setup, sheetmetal design information tools, and sheetmetal design rules
 Detail sheetmetal designs
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MODULE - 1
Introduction to the Creo Parametric Sheetmetal Design Process
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1. Introduction to the Creo Parametric Sheetmetal Design Process
Module Overview:
 In this module, you learn about the sheetmetal design process that is typically used to build a sheetmetal model in Creo
Parametric. The process is supported throughout the course modules and again followed in a course project.
 This module also introduces you to some of the basic sheetmetal features that can be used to capture your design intent for
a sheetmetal model.
Objectives:
 After completing this module, you will be able to:
 Create a primary flat wall as the base feature for a sheetmetal design.
 Create some simple secondary walls.
 Add a predefined notch and a predefined form to a sheetmetal model.
 Create a flat state for a sheetmetal model design.
 Create a drawing of the formed and flat state of a sheetmetal design.
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Figure 2 – Secondary Walls

Figure 1 – Primary Walls
Figure 3 – Other Sheetmetal Features
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Figure 5 – Detail Drawings

Figure 4 – Flat States
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2. Creating a New Sheetmetal Part in Assembly Mode
You can create a new sheetmetal model in Assembly mode. When you are working inside of an existing
assembly, you can click the Create icon to open the Create Component dialog box.
Figure 1 – Creating a New Component in an Assembly
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3. Creating a New Sheetmetal Model in Part Mode
You can click the New icon, select the Sheetmetal radio button, and type a File name. You can then
either click OK and use the default sheetmetal template part or you can clear the Use default template check
box, click OK, and then browse for the sheetmetal template part you want to use. Note that you can use the
template_sheetmetalpart config option to specify the default template.
Figure 1 – Creating a New Sheetmetal Model in Part Mode
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MODULE - 2
Creating Primary Sheetmetal Wall Features
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2. Creating Primary Sheetmetal Wall Features
Module Overview:
A critical building block for every sheetmetal model is the creation of a primary wall feature. Since it is the first sheetmetal feature in a
model, it does not need to reference any other sheetmetal features. It also sets the thickness of the entire sheetmetal model.
In this module, you will explore a number of different methods of creating primary walls. You will also learn about how these primary
wall types can be created after an initial primary wall exists. These walls are called unattached walls.
Objectives:
 Understand the difference between primary and secondary walls.
 Understand the difference between attached and unattached walls.
 Create planar primary walls.
 Create extruded primary walls.
 Create revolved primary walls.
 Create blend primary walls.
 Create offset primary walls.
 Understand other less common types of primary walls.
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Understanding Sheetmetal Wall Features
Figure 2 – Secondary Wall Attached Along Green Edge

Figure 1 – Primary Wall No References
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Understanding Sheetmetal Wall Features
Figure 4 – Secondary Wall Merged at Both Ends

Figure 3 – Two Unattached Primary Walls
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Creating Planar Walls
You can use the Planar icon for this type of feature, and it is located in the Shapes group section of the ribbon and in the mini toolbar.
Figure 1 – Completed Planar Wall Figure 2 – Planar Wall Icon in the Ribbon Figure 3 – Planar Wall Icon in the Mini Toolbar
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Extruded Sheetmetal Wall Features
An extruded wall is created by taking a sketch you create and extending it normal to the sketch plane. This creates a surface to which you can
add sheetmetal thickness to the inside or outside. You can use the Extrude icon for this type of feature, and it is located in the Shapes
group section in the ribbon and in the mini toolbar.
Figure 1 – Competed Extruded Primary Wall
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Revolved Sheetmetal Wall Features
A revolved wall is created by taking a sketch you create, and rotating it about an axis. This creates a surface to which you can add sheetmetal
thickness to the inside or outside.
You can use the Revolve icon to create this type of feature, and it is located in the Shapes group drop-down menu in the ribbon and in the
mini toolbar.
Figure 1 – Completed Revolved Wall Figure 2 – Revolved Wall Icon in the ribbon Figure 3 – Revolved Wall Icon in the mini toolbar
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Blend Sheetmetal Wall Features
You can create a blended wall by connecting two or more sketched sections together. You can also connect two or more pre-existing sketches
together, and the sketches do not have to be parallel to each other. This creates a surface to which you can add sheetmetal thickness to the inside
or outside.
You can use the Blend icon for this type of feature, and it is located in the Shapes group of the ribbon.
Figure 1 – Completed Blend Primary Wall Feature Figure 2 – Blend Wall Icon Location
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Creating Offset Walls
An offset wall is created by specifying an existing surface, and the direction and distance you wish to offset.
This creates a new surface to which you can add sheetmetal thickness to the inside or outside. You can click the Offset icon, located in the
Editing group of the ribbon, for this type of feature.
Figure 2 – Completed Offset Primary Wall

Figure 1 – Surface Feature
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Advanced Primary Walls
Figure 2 – Swept Blend

Figure 1 – Variable Section Sweep
Figure 4 – Boundary Blend

Figure 3 – Helical Sweep
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MODULE - 3
Creating Secondary Sheetmetal Wall Features
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Creating Secondary Sheetmetal Wall Features
Module Overview:
Once you have created at least one primary wall in a sheetmetal model, you can begin creating secondary walls and attaching them to the
model. In this module, you will explore a number of different methods of creating secondary walls.
Objectives:
 Understand the general characteristics and types of secondary walls.
 Create secondary flat walls.
 Create secondary flange walls.
 Create secondary extruded walls.
 Create secondary twist walls.
 Create secondary extended walls.
 Create secondary merge walls.
 Understand and create partial and overextended walls.
 Understand and apply the different types of relief to walls when necessary.
 Understand and use the different dashboard options that are available for flat and flange walls.
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Understanding Secondary Walls
You can create secondary walls by referencing at least one primary wall. A secondary wall is always a child feature of the primary wall it
references.
You can create any primary wall type as a secondary wall. In addition to the primary walls, there are six other wall features that can ONLY
be created as secondary walls:
Figure 2 – Flange Figure 3 – Extruded

Figure 1 – Flat
Figure 6 – Merge
Figure 5 – Twist
Figure 4 – Extend
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Creating Secondary Flat Walls
You can create a secondary flat wall by referencing a straight edge on an existing wall. You can then specify a number of different elements
that determine the final configuration of the flat wall.
First you should specify the overall shape of the wall. The wall is always created as an open loop sketch that is attached to the referenced
straight edge. You can select a predefined sketch shape or define the sketch yourself.
You can select from the following predefined shapes:
Figure 2 – Trapezoid
Figure 1 – Rectangle
Figure 4 – T
Figure 3 – L
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Using Flange Walls
A flange wall is a folded sheetmetal wall that is attached to straight or swept edges. You select an edge or a set of adjacent edges (they
must form a continuous path) to which you will attach the flange wall. You can then specify the profile of the wall as well as other
dashboard options.
There are three basic types of flange wall profiles:

Frequently Used Shapes – The frequently used shapes that are available as predefined geometry are the I, Arc, and S shapes.
Figure 3 – S
Figure 1 – I Figure 2 – Arc
Figure 4 – Z Figure 5 – Open
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Using Flange Walls
Figure 9 – Duck
Figure 6 – Flushed Figure 7 – Joggle Figure 8 – C
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Using Flange Walls
Flange Wall Dashboard Options
In addition to having the dashboard options that are common to both secondary flat and secondary flange walls, you can also set the
following options that are specific to flange walls:
Figure 10 – Miter Cuts Figure 11 – Miter Cuts with Deform Areas Figure 12 – Open
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Using Flange Walls
Flange Wall Dashboard Options
Figure 14 – Gap
Figure 13 – Close corner
Figure 16 – Overlap
Figure 15 – Blind
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Using Extruded Walls
Flat and flange secondary walls enable you to automatically add a bend at the attachment edge. However, if you use flat and flange type walls you
can only add constant radius type bends. If you need to create an elliptical or any other non-circular type bend, you can use the Extrude tool
in sheetmetal to create such a wall. An example of an elliptical bend wall is shown in Figure 1.
Figure 1 – Elliptical Bend Example Figure 2 – Wrong side Thickness Figure 3 – Invalid Attachment
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Wall Dashboard Options
 Several dashboard options common to secondary flat walls and secondary flange walls are available to enable you to fully capture your design
intent in a Creo Parametric sheetmetal model. Consider the options in the list below and how they might relate to capturing your design intent:
 Placement – The sketch (for flat walls) or the edge chain (for flange walls).
 Shape – The shape is used to build the wall. The Shape option also enables you to flip the sketch profile in the flange walls.
Figure 2 – Offset: Add to Part Edge

Figure 1 – Offset: None
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 Automatic – This setting offsets the new wall and trims the wall it is attached to so that the new wall's farthest extent aligns with the old location of the
attachment wall's edge.
 By value – This setting enables you to offset the wall a specific distance by using a drag handle or adjusting the numeric offset value.
Figure 4 – Offset: By Value

Figure 3 – Offset: Automatic
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 Thickness Side – The Change Thickness Side icon on the dashboard enables you to change the thickness of the sheetmetal material to the other side of a
sketch plane for flat walls, or to the other side of the sketch for flange walls. The practical application of this can be seen in Figures 5 and 6
Figure 5 – Thickness Inside Figure 6 – Thickness Outside
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Using Partial and Overextended Walls
 By default, Creo Parametric creates full walls when you create a new secondary flat or secondary flange wall. A full wall is a wall that attaches to the entire
edge or edge chain that you reference for attachment when building the wall.
Figure 3 – Partial Wall

Figure 2 – Overextended Wall
Figure 1 – Full Wall
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Understanding Relief
There are two primary types of relief available for secondary walls:
 Bend Relief – Relief added when a bend meets a wall.
 Corner Relief – Relief added where multiple non-tangent adjacent walls fold next to each other.
Figure 1 – Rip Bend Relief Figure 2 – Stretch Bend Relief
Figure 4 – Obround Bend Relief

Figure 3 – Rectangular Bend Relief
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Understanding Relief
There are two primary types of relief available for secondary walls:
 Bend Relief – Relief added when a bend meets a wall.
 Corner Relief – Relief added where multiple non-tangent adjacent walls fold next to each other.
Figure 1 – No Corner Relief Figure 2 – V notch Corner Relief Figure 3 – Circular Corner Relief Figure 4 – Rectangular Corner Relief
Figure 5 – Obround Corner Relief Figure 6 – Normal Corner Relief Figure 7 – Square Corner Relief
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Creating Twist Wall Features
Twist walls enable you to create spiraling or coiling sections of sheetmetal. You can do this by clicking the Shapes group drop-down menu in the ribbon and
selecting Twist . Select a straight edge to attach the twist wall to. By default the twist wall width value is the same as the length of the edge selected. You can
specify the following additional dimensions:
Figure 1 – Trimmed Ends Figure 2 – Twist Axis Centered About Wall Width Figure 3 – Datum Point Specified as Twist Axis Location
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Extending and Trimming Walls
You can use Extend to lengthen or shorten existing walls. You can extend or trim the wall from a straight edge on an existing wall to either a planar surface
or a specified distance. Typically Extend is used at corners to close gaps between walls and model various overlap conditions, enabling you to fully express
your design intent in a Creo Parametric sheetmetal model.
Figure 1 – Extending an Edge Figure 2 – Extend Adjacent Surface and Along Boundary Edge Figure 3 – Using Extend to Trim an Edge
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MODULE - 4
Bending and Unbending Sheetmetal Models
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Bending and Unbending Sheetmetal Models
Module Overview:
While manufacturing sheetmetal parts, you bend flat sheets using bending tools. Creo Parametric enables you to create bends
and other geometry to reflect the true manufacturing process. You are able to unbend developable walls and bends. You can
create Bend Back features that can return unbent surfaces to their formed position. Also, you can create flat states which
creates a flat and formed version of a part model.
Objectives:
 Create angle and roll type bends.
 Apply the Regular, Transition, and Planar options for bends.
 Create planar bends.
 Unbend models with the Unbend tool.
 Reform models with the Bend Back tool.
 Use the Flat Pattern tool.
 Create flat states.
 Create split area features.
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Creating Bend Features
While manufacturing sheetmetal parts, you bend flat sheets using bending tools. Creo Parametric enables you to create bends
and other geometry to reflect the true manufacturing process. You can bend a sheet using various tools, such as angle bend or
roll bend. You use bend lines to determine the location and shape for the bend geometry in your sheetmetal parts. A bend line
is also a reference point to calculate the developed length.
Figure 1 – Angle Bend Figure 2 – Angle Bend From Edge Figure 3 – Roll Bend
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Adding Transition to Bends
A transition area shapes one section of a sheetmetal surface while leaving another section flat or with different bent
conditions.
Figure 1 – Original Model with Roll Bend Figure 2 – First Transition Added Figure 3 – Second Transition Added
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Bending in Multiple Planes
You can create bends over multiple co-planar surfaces and across gaps.
The surfaces must be co-planar, and the bending only occurs where the bend line touches the co-planar surfaces.
Figure 1 – Original Model Figure 2 – Bend Line Figure 3 – Completed Bend
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Creating Planar Bends
A planar bend creates a bend feature around an axis that is perpendicular to the driving surface and the sketching plane. The
neutral point for planar bends is placed according to the current Y-factor and bend tables are not applicable. You can create a
planar bend for both angle and roll type bends, as shown in Figure 1 and Figure 2.
Figure 1 – Angle Planar Bend Figure 2 – Roll Planar Bend Figure 3 – Completed Bend
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Creating Unbend Features
You can unbend both a wall and a bend as long as the material is able to unbend. You cannot unbend non-ruled surfaces using a
regular unbend feature. After you unbend an area, you can continue to add features, such as cuts and rips. The features
following the unbend are children of, or dependent on, the unbend feature.
Figure 1 – Original Model Figure 2 – Selected Xsec Curve and Resulting Unbend Figure 3 – Sketched Xsec Curve and Resulting Unbend
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Creating Bend Back Features
You create the Bend Back feature to return unbent surfaces to their formed position. As a rule, you should only bend back a
fully unbent area. When a sheetmetal wall overlaps and intersects in the unbent position, the system highlights it and issues a
warning.
Figure 1 – Original Model Figure 2 – Unbend and Extrude Feature Figure 3 – Bend Back: Default and Keep Contour
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Previewing and Creating Flat Patterns
A flat pattern is similar to unbending all walls. It flattens any curved surface, whether it is a bend feature or a curved wall
Figure 1 – Default Model and Flat Pattern Figure 2 – Creating a Flange Figure 3 – Flat Pattern Updates to Flatten Flange
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Creating Flattened Representation
The process of defining a simplified representation of a sheetmetal part in the flattened state, while having the master
representation in the formed (bent) state, is simplified.
Figure 2 – Manage Flat Pattern View

Figure 1 – Flattened Pattern Preview
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Creating Split Area Features
You can create the deformation area before unbending the section by clicking Split Area . This tool enables you to sketch
the desired deformation area.
Figure 1 – Original Model Figure 2 – Select Existing Surface Patch Figure 3 – Select Deformation Area
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MODULE - 5
Sheetmetal Form Features
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Sheetmetal Form Features
Module Overview:
A form is a sheet metal wall molded by a template (reference part). Merging the geometry of a reference part to the sheet
metal part creates the form feature. Creo Parametric enables you to use assembly type constraints to determine the location of
the form in your model.
Formed models can be unbent. In some cases, the model has to be ripped or deformed to enable flattening.
Objectives:
After completing this module, you will be able to:
Use punches and dies to form your models.
Utilize Model Annotations to create punch and die forms.
Create sketched forms.
Flatten form geometry.
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Punch Form Features
A form is a sheetmetal wall molded by a template (reference part). Merging the geometry of a reference part to the sheetmetal
part creates the form feature. You use assembly-type constraints to determine the location of the form in your model.
Figure 1 – Punch Reference Model Figure 2 – Wall Formed with Punch Figure 3 – Creating Rips in the Geometry
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Utilizing Punch Model Annotations
Define Punch Model annotations to speed up placement. In this type of annotation, you can select surfaces to predefine those
that will be removed when using the model for a punch in a sheetmetal part.
Figure 1 – Creating Annotation Figure 2 – Punch Model Created
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Creating Die Forms
You can create impressions in a sheetmetal wall using solid parts as Die Forms.
A die form is a collection of geometry forming a pocket within a planar surface on a solid model. The sheetmetal is then drawn
into the pocket geometry, leaving an impression
Figure 2 – Punch Model Created

Figure 1 – Creating Annotation
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Creating Die Forms Using Annotations
Within the die form model, you can use an annotation feature to predefine the die shape surfaces and the surfaces to be
excluded.
Figure 1 – Original Sheetmetal Model Figure 2 – Die Form with Annotation Surfaces Figure 3 – Completed Sheetmetal Model
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Creating Sketched Forms
Sketched forms allow you to quickly create forms that are sketch based rather than having to use a separate model. Creating a
sketched form is similar to creating an extruded feature. The sketched form allows for the use if sketch libraries for common
shapes
Figure 2 – Sketch for Piercing Form Figure 3 – Formed Sheetmetal Model

Figure 1 – Sketch for Punch Form
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Flattening Forms
In some cases, you may have to return a sheetmetal model to its original flat state after you have placed form features on it.
The form features do not get flattened along with the bend features in the model.
Figure 1 – Original Model (Unbent) Figure 2 – Flatten Form
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Utilizing Dependency Control with Punch and Die Forms
You can use dependency control to control updates of inherited punch and die forms.
Figure 1 – Update Control Options Figure 2 – Update Control Set to Manual Update Figure 3 – Update Control Switched to Automatic Update
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MODULE - 6
Modifying Sheetmetal Models
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Modifying Sheetmetal Models
Module Overview:
Creo Parametric enables you to remove material in various ways to establish cuts, openings, and relief where necessary in your
designs.
Objectives:
After completing this module, you will be able to:
Remove material from a model using cuts.
Create notches and punches to remove material.
Create corner relief.
Create rips to help flatten unbendable geometry.
Create edge bends on sharp corners.
Join, pattern, and mirror walls.
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Sheetmetal Cuts
You can remove the material from a sheetmetal part using cuts. The cut is made normal to the sheetmetal surface, as if the part
were completely flat, even if it is in a bent state. The cut adopts the sheetmetal material's natural behavior, like bending and
warping, when the part is bent .
Figure 2 – Unbent State

Figure 1 – Create Cuts in a Design State
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Notches and Punches
You use notches and punches as templates to cut and relieve sheetmetal walls. You place notches on the edges and punches in
the middle of the sheetmetal wall. Notches are used to relieve material that interferes with bending in places such as the
corners of flanges.
Figure 2 – Punch Used to Create Holes

Figure 1 – Notch Used for Relief
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Creating Multiple Bend Reliefs
Reliefs are created as appropriate, and not just at bend line ends.
Figure 1 – Bend Line Figure 2 – Bend Created Figure 3 – Multiple Reliefs
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Bend Line Relief Placement
By using relief, you can create different results for bend lines that do not reach the edges of the sheetmetal wall:
Figure 1 – Bend Line Figure 2 – Obround Reliefs Both Sides Figure 3 – No relief Right Side
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Creating Corner Relief
Corner relief helps prevent unwanted deformation by controlling the sheetmetal material behavior. To utilize the corner relief
option, you must have at least one ripped edge and Annotation Display and Corner Relief Notes enabled.
Figure 2 – No Relief Figure 3 – Normal Relief Figure 4 – Circular Relief

Figure 1 – V notch Relief
Figure 7 – Obround Relief

Figure 6 – Rectangular Relief
Figure 5 – Square Relief
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Creating Rip Features
You can unbend sheetmetal geometry using rips. A rip shears or tears your sheetmetal walls, especially along seams. If your
part is a continuous piece of material, it cannot be unbent without ripping the sheetmetal.
Figure 2 – Creating a Surface Rip Feature

Figure 1 – Creating an Edge Rip
Figure 4 – Creating a Rip Connect

Figure 3 – Creating a Sketched Rip
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Creating Edge Bends
An edge bend converts non-tangent edges to bends. Depending on the material side you choose to thicken, some edges appear
rounded while others have sharp edges. The edge bend option enables you to quickly round the edge.
Figure 3 – Edge Bend with Obround Relief

Figure 1 – Part with Two Edge Bend Sets Figure 2 – Partial Edge Bend Applied
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Joining Walls
You can use Join to combine two non-connected sheetmetal walls that intersect, as shown in Figure 1. In the Model ribbon, you
can select Join from the Editing group drop-down menu or select the two walls to intersect and click Join from the
mini toolbar. The system then determines the resulting intersection.
Figure 1 – Two Non-connected Walls Figure 2 – Multiple Flip Arrows for Trimming Geometry Figure 3 – Bend Radius Automatically Added
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Mirroring Walls
You can use the mirror option to create symmetric models.
Figure 1 – Original Model Figure 2 – First Mirror Created Figure 3 – Second Mirror Created
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Using Conversion Features
If a converted part is not developable, you can either create individual features to make it developable, such as rips and corner
reliefs, or you can use the Conversion tool to add alterations, such as rips, bends, and corner relief.
Figure 1 – Original Model Figure 2 – Conversion Feature Created Figure 3 – Creating a Flat Pattern
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MODULE - 7
Detailing Sheetmetal Designs
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Detailing Sheetmetal Designs
Module Overview:
A flat state is a completely unbent copy of your part. It streamlines the creation of flat patterns needed in
manufacturing because you can create any number of flat states at any time in your design process, whether
your part is fully formed or fully flat. Using multi-model drawings, you can add views of both flat and formed
states.
Objectives:
After completing this module, you will be able to:
Add flat and formed views to a drawing using multi-model drawings and flat states.
Apply dimensions using the Auto Ordinate tool.
Create bend line notes.
Define the bend order sequence and create the bend order table.
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Adding Flat and Formed States
A flat state is a completely unbent copy of your part. It streamlines the creation of flat patterns needed in manufacturing
because you can create any number of flat states, at any time in your design process, whether your part is fully formed or fully
flat.
Figure 1 – Formed Model Figure 2 – Flat State Figure 3 – The Drawing
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Auto Ordinate Dimensions
You can automatically ordinate the dimensions in your drawing using the Auto Ordinate command . To use auto ordinate
dimensioning, select the Annotate tab in the Drawing ribbon. Select Auto Ordinate Dimension from the Orient
Dimension types drop-down menu in the Annotations group.
Figure 2 – Ordinate Dimensions

Figure 1 – Selected Surfaces
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Bend Line Notes
A bend line note describes the basic information about the bend type, bend direction, and bend angle. The bend line notes are
automatically created for each bend in your design. The notes are parametric and aligned with the bend, so they enable you to
easily provide drawing dimensions and bend annotations.
Figure 1 – Bend Notes
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Bend Order Tables
The four bend sequences displayed in the slide result in the Bend Table.
Figure 2 – Bent Part

Figure 1 - Bend Table
Figure 4 – Sequence 3 and 4

Figure 3 – Sequence 1 and 2
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Sheetmetal Design Using Creo 5.0

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AUTOMOTIVE

Partnering Your Vision to Success

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 Create, convert, and display the sheetmetal model

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Figure 2 – Secondary Walls

Figure 3 – Other Sheetmetal Features

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Figure 5 – Detail Drawings

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Figure 1 – Creating a New Component in an Assembly

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Figure 1 – Creating a New Sheetmetal Model in Part Mode

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Figure 2 – Secondary Wall Attached Along Green Edge

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Figure 4 – Secondary Wall Merged at Both Ends

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Figure 1 – Competed Extruded Primary Wall

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Figure 2 – Completed Offset Primary Wall

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Figure 2 – Swept Blend

Figure 4 – Boundary Blend

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Figure 2 – Flange Figure 3 – Extruded

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There are three basic types of flange wall profiles:

Figure 4 – Z Figure 5 – Open

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Flange Wall Dashboard Options

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Flange Wall Dashboard Options

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Figure 2 – Offset: Add to Part Edge

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Figure 4 – Offset: By Value

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Figure 5 – Thickness Inside Figure 6 – Thickness Outside

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Figure 3 – Partial Wall

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Figure 1 – Rip Bend Relief Figure 2 – Stretch Bend Relief

Figure 4 – Obround Bend Relief

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