Efficient sheet metal fabrication begins with thoughtful design. Even small oversights in the early stages can lead to production delays, increased costs, or unusable parts. By understanding common design pitfalls, engineers and designers can create components that are both manufacturable and cost-effective.
Thank you for reading this post, don't forget to subscribe!Placing features too close to bends
One of the most frequent errors in sheet metal design is locating holes, tabs, or notches too close to bend lines. During forming, material near these features can stretch or distort, compromising structural integrity or causing misalignment. A helpful guideline is the ‘4T rule’, which suggests keeping all features at least four times the material thickness away from any bend. This provides sufficient clearance for the material to deform cleanly during bending operations.
Sharp corners
Another often-overlooked point is internal bend radius. Avoid assuming perfectly sharp 90-degree corners; instead, include a standard bend radius equal to or greater than the sheet thickness in your design. Doing so helps prevent cracking and minimises the need for specialised tooling. Companies such as https://dkmsheetmetal.co.uk/ can help you avoid these pitfalls.
Incorrect material choices and insufficient detailing
Material selection should align with the intended use of the part; for example, mild steel may be adequate for indoor applications, but corrosive environments call for alternatives such as stainless steel or coated metals. Failure to consider environmental exposure can result in premature corrosion or structural failure.
Incomplete CAD files
Equally important is providing full hardware and finish specifications within the CAD file. Leaving out information such as fastener types, coating preferences, or weld instructions can cause delays and miscommunication. Considerations around weld access, finish compatibility, and structural load must be addressed during the design stage.
Designers are encouraged to familiarise themselves with health and safety implications when working with metal, as outlined in the HSE’s guidance for safe metalwork. These considerations are particularly relevant when dealing with complex assemblies or structural elements.
Sheet metal fabrication works best when design, material, and process are aligned. Avoiding these common mistakes can help ensure projects are completed efficiently, with fewer complications and better results.