The 3:1 Rule for Precision Sheet Metal punch forming (Updated for 2024)

Last updated on February 1st, 2024 at 08:47 am

Punch forming is a highly efficient capability for adding formed features such as louvers and embossments to precision sheet metal parts.

The process involves sandwiching a piece of sheet metal between a punch and a die. Although it’s relatively straightforward, there is one design tip that can help you get your punched sheet metal prototypes as quickly as possible: following the 3:1 rule.

The 3:1 Rule for Sheet Metal Punching

The 3:1 rule states that when designing a formed feature in a precision sheet metal part, the feature's height should be no more than 3x the material thickness above the material surface.

For example, if you have a part that measures 0.060" thick and you want to add a louver that's 0.375" high above the material surface, it just won't work. We can't run the part in the punch press when the features are too high because the punch isn’t designed to work with these dimensions. Instead, you’d want to make the louver 0.180” high, which is 3x the material thickness.

What If You Can’t Follow the 3:1 Rule? 

Understandably, there are times when customers can’t easily follow the 3:1 rule, in which case there are two paths forward:

1. Performing a stamping operation with custom tooling

If you absolutely need a specific feature that violates the 3:1 rule, we can perform a stamping operation with custom tooling—though this approach will cost both time and money.

Custom tooling is expensive and can take weeks to arrive. In most cases, it’s hard for customers to justify spending thousands of dollars for this solution—especially for sheet metal prototypes.

2. Revising the design

A better option is usually to revise the design to achieve the required functionality while accommodating the 3:1 rule.

For example, louvers are used for various applications (e.g., downspouts, gutters, vents,

windows), and their primary function is simple: providing proper airflow. Some customers design louvers that are too high in an effort to maximize the airflow in a sheet metal prototype. We've seen engineers solve this issue by adding more louvers to the part and lowering the height of each one. This way, the customer meets airflow specifications, and we can make the part quickly using our punch press.

Customers may also decide to revise their designs slightly when embossments—features commonly used to maintain a specific distance between parts—violate the 3:1 rule. We might suggest spacers as a better alternative for your sheet metal prototype in those cases.

Whenever possible, Approved Sheet Metal will be proactive about recommending minor adjustments to make your life easier. We’ll contact you to talk through any potential concerns so that, no matter what, you get the exact parts you need.

Whether you’re looking for punch forming or other precision sheet metal fabrication services, our team is standing by to get started on your next project. Request a quote today!