Optimizing Sheet Metal Designs: 5 Tips for Mechanical Engineers

Last updated on July 2nd, 2024 at 09:14 am

Sheet metal fabrication is a highly versatile process for creating durable parts, ranging from single prototypes to large-scale production runs. As a mechanical engineer, optimizing your sheet metal designs can lead to cost-effective solutions without compromising quality. In this article, we’ll explore five valuable tips tailored to help you enhance efficiency and reduce costs in your projects, all within the expertise of Approved Sheet Metal.

1. Material Selection Matters

Material cost significantly impacts overall part costs. Carefully choose the appropriate material for your project and consider utilizing stock sizes to minimize waste. For prototyping, contemplate using materials like Aluminum 5052 instead of more expensive options such as 304 stainless steel. Check Approved Sheet Metal’s comprehensive list of available materials to make informed decisions based on your project requirements.

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2. Design with Standard Gauges in Mind

When designing your sheet metal parts, adhere to standard sheet metal gauges. Approved Sheet Metal can manufacture sheet metal parts up to ¼” (6.35mm) in thickness, depending on the part’s geometry. Using thicker metals may impose limitations on achievable bends, so designing to common gauges ensures optimal manufacturability. Familiarize yourself with Approved Sheet Metal’s capabilities and constraints to streamline your design process.

3. Embrace Simplicity in Bends

Simplicity is key in optimizing sheet metal fabrication costs. Design your parts with straightforward angled bends, featuring a radius equal to or greater than the sheet’s thickness. Complex designs tend to incur higher costs, and small bends on large, thick parts may lead to inaccuracies. Explore Approved Sheet Metal’s Design Guide for sheet metal, providing valuable best practices for creating cost-effective and precise sheet metal pieces.

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4. Strategically Manage Tolerances

Carefully assess the critical features of your part to determine necessary tolerances. Excessive tolerance callouts on various features, such as radii, hole diameters, and distances, can escalate manufacturing costs. To reduce expenses, assign tolerances only to mission-critical features and surfaces. Approved Sheet Metal’s expertise ensures that your parts meet the required specifications without unnecessary additional costs.

Recommended Default Sheet Metal Tolerances

DIM	Tolerance (MM)	Tolerance (Inches)	Description
A	± 0.13	± 0.005	Sheared Edge to Hole
B	± 0.13	± 0.005	2 Holes on One Surface
C	± 0.25	± 0.010	Formed Edge to Hole
D*	± 0.76	± 0.030	Holes Across 2 Bends
E*	± 0.76	± 0.030	Holes Across 4 Bends
F	± 0.25	± 0.010	Sheared Edge to Bend
G	± 0.38	± 0.015	Across 2 Bends
H*	± 0.76	± 0.030	Formed Part

Noted dimensions are to be taken while the part is in a restrained condition. Noted dimensions are for parts within a 12″ envelope.
* Dimensions D, E and H are not recommended forms of dimensioning
These tolerances are recommended and best practices. We can obtain tighter tolerances (depending on part geometry/ construction), contact us for more information Download PDF

5. Ensure Consistent Bend Orientation

Maintain uniform bend orientation for parts in the same plane to avoid unnecessary reorientation during fabrication. Consistent bend radii contribute to cost-effectiveness and precision. Approved Sheet Metal provides detailed insights on the basics of bending sheet metal in their blog post, offering valuable information for engineers seeking optimal design practices.

Sheet Metal Fab Forming Videos

Sheet Metal Part Design for Manufacturing Tip

BENDS

Bending sheet metal parts is a process that is completed by utilizing press brakes and our very skilled press brake operators. At Approved Sheet Metal, we can hold tolerances of +/- 1 degree on most bend angles. The ideal bend radius on formed parts is 0.030 in., this ensures that you can get consistent, quality parts that will maintain solid structural integrity.

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Optimizing Sheet Metal Fab Design FAQ

Why is material selection important in sheet metal fabrication?

Material selection significantly impacts overall part costs and manufacturability. Choosing appropriate materials and utilizing stock sizes can minimize waste and reduce costs. For example, using Aluminum 5052 for prototyping instead of more expensive materials like 304 stainless steel can be more cost-effective.

What are the benefits of designing with standard gauges in mind?

Designing with standard sheet metal gauges ensures optimal manufacturability and cost-efficiency. Approved Sheet Metal can handle parts up to ¼” (6.35mm) in thickness, but thicker metals may limit achievable bends. Sticking to common gauges helps streamline the design process and avoid manufacturing complications.

How can simplicity in bends reduce fabrication costs?

Simple, straightforward angled bends with a radius equal to or greater than the sheet’s thickness are easier and cheaper to manufacture. Complex designs and small bends on large, thick parts can lead to higher costs and inaccuracies. Embracing simplicity in bends helps maintain precision and cost-effectiveness.

Why is it important to strategically manage tolerances in sheet metal design?

Assigning excessive tolerances to various features can increase manufacturing costs. By focusing on tolerances for only mission-critical features and surfaces, you can reduce expenses without compromising the part’s functionality. Approved Sheet Metal’s expertise ensures that parts meet the required specifications efficiently.

How does maintaining consistent bend orientation benefit the fabrication process?

Consistent bend orientation for parts in the same plane avoids unnecessary reorientation during fabrication, enhancing cost-effectiveness and precision. Uniform bend radii contribute to easier and more accurate manufacturing. Approved Sheet Metal provides detailed guidelines on optimal bend practices to help engineers design efficiently.