Common Mistakes to Avoid During Designing Sheet Metal Parts

Sheet metal fabrication is the process of creating parts and components by cutting, bending, and shaping sheets of metal. The design of sheet metal parts is crucial for their functionality, durability, and manufacturability. However, even experienced designers can make mistakes that can affect the quality and cost-effectiveness of sheet metal fabrication. In this blog, we will discuss some common mistakes to avoid during designing sheet metal parts.

Precision Sheet Metal Fabrication

Ignoring Manufacturing Constraints:

One of the most common mistakes in sheet metal design is ignoring manufacturing constraints. Sheet metal parts are made using various processes and equipment that have limitations and requirements that must be considered during design. For example, the thickness of the metal, the size of the bending radius, and the placement of holes and cutouts can affect the performance of the fabrication process.

Ignoring these constraints can result in parts that are difficult or impossible to manufacture. Therefore, it is essential to involve fabricators in the design process and to consider their expertise and feedback.


Not Understanding Material Properties:

Another common mistake is not understanding the material properties of the sheet metal used in the design. Sheet metal comes in different alloys and grades, each with its own mechanical, chemical, and thermal properties. These properties affect the behavior and performance of the parts in various conditions, such as temperature changes, corrosion, and stress.

Therefore, designers must select the right material for the application and consider its properties in the design. For example, using a low-grade metal for a high-stress application can result in deformation or failure of the part.


Inaccurate Measurements and Tolerances:

Accurate measurements and tolerances are crucial for the quality and precision of sheet metal parts. However, many designers make mistakes related to measurements and tolerances, such as not specifying them correctly, not considering the fabricator’s capabilities, or not verifying them during the manufacturing process.

As a result, parts can have incorrect dimensions, misaligned holes, or poor fit and finish. Therefore, designers must be familiar with the measurement units and standards, specify the tolerances clearly, and verify the dimensions during quality control.


Poor Design for Assembly:

Sheet metal parts are often used in assemblies that require multiple components to fit together seamlessly. However, poor design for assembly can lead to difficulties in assembling or disassembling the parts, or even compromising their functionality.

Common mistakes in assembly design include not considering the order of assembly, not providing clearance and access for fasteners, and not aligning mating surfaces properly. Therefore, designers must consider the assembly process as part of the design and ensure that the parts fit together precisely and efficiently.


Lack of Communication with Fabricators:

Finally, lack of communication between designers and fabricators can lead to misunderstandings, delays, and rework in the fabrication process. Designers must provide clear and detailed specifications and drawings that convey their intent and requirements accurately.

Fabricators, on the other hand, must communicate any issues or suggestions regarding the design, materials, or manufacturing process. Therefore, designers must establish a good working relationship with the fabricators and maintain open communication channels throughout the design and fabrication process.


5 Tips for Designing Sheet Metal Parts:

In addition to avoiding common mistakes, there are some best practices and tips that can help designers create better sheet metal parts. These tips include:

  • Keep it simple: Avoid unnecessary features, bends, and cuts that can increase the complexity and cost of the part.
  • Minimize material waste: Use the optimal sheet size and layout to reduce the amount of scrap and leftover material.
  • Use standard features: Utilize standard holes, cutouts, and bends to reduce the cost and lead time of tooling and setup.
  • Consider the aesthetics: Design parts that are visually appealing and consistent with the brand and product design.
  • Test and validate: Use simulation and prototyping tools to verify the performance and manufacturability of the design before production.


New Technologies and Trends in Sheet Metal Design:

The sheet metal fabrication industry is constantly evolving, and new technologies and trends emerge to improve the efficiency, quality, and sustainability of the process. Some of the latest developments in sheet metal design include:

Additive manufacturing: Using 3D printing and other additive technologies to create complex and customized sheet metal parts.

Automated nesting and cutting: Using AI-powered software to optimize the nesting and cutting of sheet metal parts and reduce material waste.

Lightweighting: Designing sheet metal parts that are lighter and more efficient by using advanced materials and geometries.

Sustainability: Designing sheet metal parts that are environmentally friendly and reduce the carbon footprint of the fabrication process.

Beska’s Sheet Metal Fabrication Capability

As a custom sheet metal fabrication service provider, we can provide a wide range of services: Laser cutting, bending, welding, and finishing. From prototyping to large-scale production, we offer cost-effective solutions to meet your unique needs. Trust us to bring your ideas to life with precision and reliability.

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