Bending is a critical process in sheet metal fabrication, transforming flat material into functional components through carefully applied force. However, without precise design considerations, the process can result in material deformation, inaccuracies, or increased production costs. Below are practical tips to help ensure clean, reliable bends and a more efficient fabrication process.
Use appropriate bend radii and spacing
A fundamental rule in bending is to keep the internal bend radius at least equal to the material thickness. This helps prevent cracking and ensures structural consistency throughout the part. Using the same radius for all bends can also reduce tool changes and speed up production.
Bends placed too close to one another-or near features like holes and slots-can lead to warping or misalignment. To maintain dimensional accuracy, designers should avoid successive bends unless necessary. When they are required, allow sufficient spacing between them and consider extending the intermediate section. Additionally, holes should be positioned a minimum of 2.5 times the material’s thickness from any bend to avoid distortion. In more complex parts, keeping bends in the same plane can minimise the need for part reorientation during manufacture, reducing both time and cost.
Design with process safety and precision in mind
Safety and accuracy are tightly linked in sheet metal fabrication. Proper allowances for bend reliefs, flange lengths, and notch spacing ensure parts form correctly and help reduce the risk of sharp edges or structural weaknesses. For instance, flange lengths should be at least four times the material thickness to provide adequate support during bending.
In operations involving mechanical presses or CNC bending machines, the setup must account for the material’s yield strength, thickness, and required bend angle. According to Hytek Marketing, safety features and clear operating protocols are essential to prevent injury and ensure a smooth process.
For designers working with manufacturing partners such as https://dkmsheetmetal.co.uk/, a strong understanding of bending principles and material behaviour can significantly improve part quality and production efficiency.
Ultimately, attention to these details during the design stage leads to fewer errors, faster turnaround times, and better-performing components.
+ There are no comments
Add yours