Designing custom sheet metal parts is complex and requires attention to detail. Optimizing the manufacturing process yields durable final products while saving time and resources. Use these five tips for designing custom sheet metal parts to meet performance requirements.
1. Choose the Right Material for Your Application
The material is one of the most critical decisions in sheet metal design. Tensile strength, corrosion resistance, ductility, and weight influence the performance of the part. Aluminum is lightweight and corrosion-resistant, making it ideal for aerospace applications. Stainless steel offers excellent strength and durability for heavy-duty products.
Consider the environmental conditions, stress factors, and operational requirements. You can consult sheet metal fabricators from Sytech to ensure the material you choose is suitable for the intended manufacturing processes.
2. Consider Bend Radii and Bend Reliefs
Appropriate bend radii and bend reliefs avoid fractures or deformities during the forming process. The bend radius should equal the material’s thickness to prevent cracking or unwanted stress on the material.
Bend reliefs at edges near bends eliminate the risk of tearing or distortion. For example, a two-millimeter aluminum sheet should have a minimum bend radius of two millimeters for optimal results. Designing with appropriate bend features improves the quality of your part and speeds up manufacturing.
3. Account for Tolerances and Material Thickness
Accurate tolerances and consistent material thickness are vital for achieving tightly engineered designs that fit within assemblies. Understand the natural variations of materials and manufacturing processes to establish realistic tolerances that maintain functionality without constraints.
Similarly, consider material thickness variations due to coatings or treatments, as minor discrepancies could affect assembly and performance. Always communicate your tolerance requirements clearly with your manufacturer.
4. Optimize Your Design for Manufacturing
Design for manufacturing (DFM) principles should guide every sheet metal part design stage.
- Simplify your geometry to reduce complexity.
- Avoid overly intricate cutouts or sharp corners that may increase production time or costs.
- Consolidate multiple components into a single part whenever possible to minimize assembly requirements.
- Align your design with the capabilities of common manufacturing techniques, such as laser cutting, punching, and bending.
5. Use Prototyping To Test Your Design
The best products go through prototyping to identify potential flaws and validate the design before full-scale production. Create a prototype to assess fit, form, and functionality while addressing potential issues such as weak points, assembly challenges, or dimensional inaccuracies.
Rapid prototyping methods, such as 3D printing or CNC machining, are cost-effective solutions for producing test models quickly. After testing and gathering feedback, iterate your design to refine and improve its performance before finalizing it for production.
Designing custom sheet metal parts requires a balance of engineering expertise and manufacturing precision. Follow these tips to meet performance standards while streamlining production. Collaborate with our team of experts to turn your ideas into high-quality, precision-engineered parts.