Design for Sheet Metal Fabrication Toolkit

Receive expert design advice to optimize your parts for sheet metal fabrication. Designing with fabrication considerations from the start helps speed up production and reduces costs across the entire product lifecycle.

Free Design Review for Sheet Metal Fabrication Assemblies

Take advantage of our 30-minute virtual meeting with a sheet metal applications engineer to refine your project. This session is ideal for addressing your questions and ensuring your design aligns with production needs.

Material suitability for application

Optimizing design for cost-effectiveness

Improving strength and durability

Best fabrication techniques for accuracy and minimal waste

Professional Part Design for Sheet Metal Fabrication

Our professional part design services for sheet metal fabrication focus on optimizing your components for cost-effective and efficient production. By considering factors like material selection, thickness, bend radii, and manufacturability early in the design process, we ensure your parts meet all functional requirements while minimizing production costs and lead times. With our expert guidance, we help you navigate complex design challenges and achieve high-quality results.

Critical Design Advisories

Follow these 4 design advisories can help you optimize production efficiency and aesthetic function of your sheet metal parts.

Minimum Flange Lengths

Minimum flange lengths are essential to securely hold a workpiece between the top and bottom die in the press brake during the forming process. The required flange length varies based on material type, material thickness, and bend radius. Please refer to the table below for specific length guidelines according to KingStar Mold’s tooling requirements.

[table “89” not found /]

Additional design considerations:

Placing Features Near Bends

Placing features strategically in sheet metal design enhances complexity and functionality, but care must be taken when positioning them near bends. As the material stretches during the forming process, features located too close to bends may experience distortion. The appropriate distance from bends depends on factors like material type, thickness, and bend radius. Refer to the table below for recommended distance guidelines to minimize distortion.

[table “90” not found /]

Additional design considerations:

Bend Radius Outside Tooling Range

KingStar Mold offers internal bend radius tooling options ranging from 0.01 in. to 1 in.

Note: As KingStar Mold primarily uses air bending technology, the actual radius on a physical part may slightly differ from the tool used during the forming process.

[table “91” not found /]

*If fast lead times are crucial, consider incorporating one of these design options into your part specifications.

Additional design considerations:

  • For parts with internal radii greater than 1 inch, KingStar Mold will employ a technique known as “bump” forming, where multiple tooling lines are used to achieve the desired bend.

Hardware Insert and Sheet Stock Compatibility

KingStar Mold offers a broad selection of PEM® fasteners for your sheet metal parts. To ensure proper installation and functionality, follow these two key guidelines for hardware insert and sheet stock material compatibility:

  • The sheet metal material should be softer than the hardware material to ensure compatibility.
  • Sufficient grip is necessary for the insert to securely seat into the sheet metal during installation.

Refer to the table below for a reference guide on compatible insert and material types.

[table “92” not found /]