Five sheet metal design mistakes and how to avoid them

Designing components for sheet metal fabrication can be complex, especially for those unfamiliar with the specific requirements of bending, cutting and finishing. A small oversight at the design stage can cause big problems during manufacturing or assembly.

Here are five common design mistakes and what to do to avoid them.

Ignoring spacing around bend lines

Placing cutouts too close to bend lines is a frequent error. When metal is bent, adjacent cutouts can become distorted, stretched or misaligned, especially if the design violates minimum bend spacing. This can prevent components from fitting correctly. Notching can help in these cases, allowing for cleaner edges and better functionality when placing cutouts near bends.

Wrong finish

Finishes serve both functional and aesthetic purposes. Powder coating is popular for its durability and colour range, while bare metal finishes like graining or media blasting offer a clean look without additional coatings. However, certain applications require chemical finishes such as passivation or conversion coating, for improved corrosion resistance or conductivity. Always match your finish to the intended environment and use. Here you can read more about surface treatments and finishes.

Powder coat thickness

Once powder coating is applied, it adds around 0.003″-0.005″ per side. This might seem negligible, but failing to account for it in your cutout dimensions can result in components not fitting correctly. Always factor in coating thickness during the design phase to avoid last-minute issues.

Bend radius too tight

Bends in sheet metal aren’t sharp corners but curves with a defined radius. If this radius is too tight for the material thickness, it can lead to cracking or deformation. Different metals have different minimum bend radii, so consult a specification guide before finalising your design.

Skipping expert resources

Many mistakes stem from a lack of information. Consulting a trusted sheet metal fabrication specialist, such as https://dkmsheetmetal.co.uk, can help you avoid costly errors and refine your design.

Getting your sheet metal design right the first time will save time, money and frustration. Understanding the basics of sheet metal fabrication is a solid foundation for successful, reliable results.