A Sheet Metal Bracket Design Guide (Updated for 2024)

Last updated on January 29th, 2024 at 12:53 pm

At Approved Sheet Metal, our sheet metal fabrication experts fabricate brackets for product developers across the country that design for a broad range of commercial, and military applications.

In this guide, we share some background on the processes we use to manufacture custom sheet metal brackets, explore different bracket types, and share tips to help you design the ideal custom brackets for your applications.

What Are Sheet Metal Brackets?

Brackets are intermediate components that attach one object to another (e.g., a shelf to a wall), align parts within an enclosure, or fortify a part by supplying extra structural support. Depending on its type, a bracket is either mounted with hardware or welded inside a sheet metal part.

Brackets are typically functional in nature but can be used for decorative purposes.

Standard Bracket Materials

We fabricate brackets from a variety of materials, including:

• Cold rolled steel
• 5052 aluminum
• Stainless steel

How Our Sheet Metal Fabrication Shop Fabricates Brackets

Sheet metal fabrication is one of the most simple and cost-effective ways to create brackets. At ASM, we use a combination of fabrication methods to manufacture exceptionally strong, durable brackets for our customers.

Cutting

First, we use our laser cutter to cut a flat piece of sheet metal to the specified size.

Forming

We then bend the cut metal piece at one or more angles, typically using a press brake, to produce the desired shape.

Punching

For brackets that will be mounted, we leverage our punch forming capabilities to create holes for mounting hardware.

Welding

Brackets designed to fortify or stiffen metal are welded into place rather than fastened.

Common Bracket Types

No matter which type of bracket you need, our sheet metal fab shop can make it. Here are the standard bracket types we fabricate:

L brackets

The most common bracket type, an L bracket has a single bend that lends it an L shape. L brackets are most often bent at a 90-degree angle but can be bent to angles up to 120 degrees.

Z brackets

Z brackets have two bends that create parallel flanges pointing in opposite directions, making a Z or double L shape. These brackets are often used to anchor parts at different levels within an enclosure or prop up parts that require air flow beneath them.

U-channel brackets

U-channel brackets have two bends at facing angles, creating a U shape. Typically much longer than L or Z brackets, they require multiple holes for mounting hardware. These brackets are ideal for mounting parallel surfaces together.

Hat channel brackets

These top hat-shaped brackets are welded inside parts made of weaker metal to keep them from collapsing inward (e.g., inside metal doors).

Gusset brackets

Like hat brackets, gusset brackets are welded inside metal parts for added fortification. Often triangular in shape, they are commonly used in architectural applications, such as bridges.

Design Considerations for Custom Brackets

Creating brackets is generally straightforward, but there are a few factors to keep in mind when designing these parts to ensure optimal results.

Material strength

Always consider the load your bracket will need to support. Will the material you’ve chosen be strong enough to accommodate it? If you need help selecting the right material for your application, our team is happy to help!

Flange proportions

For U-channel and hat-channel brackets, specific flange proportions must be maintained to prevent the part from slipping out of place in the press brake.

Design forming flanges shorter than the base flange to ensure your bracket can be pressed properly. If these proportions are reversed, we may need to acquire custom tooling to create your part, which will increase your cost.

ASM’s perfect fit flange formula can help you design foolproof flanges for your bracket!

Hole placement

One of the most common questions we get from customers designing brackets is where to place bracketry holes in relation to bends. When possible, add holes a safe distance from bends to simplify punching operations, which can help optimize costs and lead times.

Got questions about your bracket design? Ask our team, or better yet, request a design review!