10 Sheet Metal Design Mistakes You Should Avoid

Examples of Sheet Metal Design in Different Industries

Sheet metal designs are indispensable across diverse industries. Here are just a few examples of their applications to demonstrate the importance of precision in design:

• Automotive: Cars, trucks, and other vehicles rely on sheet metal for body panels, structural reinforcements, and exhaust systems.
• Aerospace: Sheet metals are used in the wings, fuselage, and structural frames of aircraft, requiring extreme precision to minimize weight while maintaining strength.
• Consumer electronics: Devices like laptops, smartphones, and household appliances use sheet metal for enclosures and casings to provide structure and protection.
• Construction: HVAC ducts, roofing panels, and structural steel components highlight the importance of durable, well-designed sheet metal structures.

These industries show how important it is to avoid design mistakes. Now, let’s look at the most common errors made during the sheet metal design process.

10 Common Sheet Metal Design Mistakes (and How To Fix Them)

Sheet metal design is a comprehensive process with all sorts of things that can go wrong along the way. Here’s what to watch for.

1. Ignoring Material Properties

Every type of sheet metal, be it aluminum, steel, or copper, has unique properties such as tensile strength, flexibility, and corrosion resistance. Designing without considering these properties can lead to a weak or unsuitable product, resulting in cracking, warping, or difficulty during the fabrication process.

Solution

Choose materials that align with the functional requirements of the product, and establish clear communication with fabricators regarding raw material specifications.

2. Overlooking Design for Manufacturability (DFM)

A design that looks great on paper may fail during production if it’s too complex or challenging for manufacturing equipment to handle. This can lead to increased production time and costs and reduced product scalability.

Solution

Collaborate with fabrication shops early in the design phase to align your design with manufacturing capabilities.

3. Incorrect Bend Radius

Misjudging the bend radius can cause cracking or distortion in the metal. A radius that is too tight is especially problematic. If left unchecked, it can result in structural issues and material fatigue.

Solution

Follow the 1x thickness rule (bend radius should be greater than or equal to 1 times the thickness of the sheet). Always check your material’s bend tolerance guidelines.

4. Poor Hole Placement

Placing holes too close to edges or bends can weaken the structure, making the product vulnerable to damage. This means reduced product strength and potential failure during use.

Solution

Maintain proper clearance by keeping holes at least twice the material’s thickness away from edges and bends.

5. Overcomplicating Features

Designers often add unnecessary details or sharp corners that make manufacturing overly complex, resulting in increased production time, higher tooling costs, and unnecessary waste.

Solution

Simplify designs where possible, replacing sharp corners with rounded ones and removing nonfunctional details.

6. Ignoring Springback Compensation

After bending, sheet metal tends to “spring back” slightly to its original shape, which can cause deviations from the intended design.

Solution

Account for springback by overbending slightly and working with experienced fabricators to determine proper compensation levels.

7. Failing To Optimize for Weight

Unnecessarily heavy designs can result in inefficiencies, especially in the aerospace and automotive industries where weight impacts fuel efficiency. Such issues can increase costs due to material waste and reduced functionality.

Solution

Use lightweight materials where feasible, and remove excess mass with strategic cutouts, balancing strength and durability.

8. Neglecting Finishing Options

Failing to consider how finishing processes like powder coating or anodizing will affect design dimensions or durability can lead to product defects. This can potentially lower corrosion resistance and lead to improper fits.

Solution

Incorporate finishing tolerances into your design, and specify clear coating and finishing requirements.

9. Skipping Prototyping

Skipping the prototyping phase can lead to catastrophic design flaws being identified only after production has begun. This often means escalating costs, wasted materials, and delays.

Solution

Use rapid prototyping techniques, such as laser cutting, to test and refine designs early on.

10. Ignoring Tolerances

Overly tight tolerances can significantly increase manufacturing costs, while loose tolerances may result in poor-quality assemblies or even part failure.



Solution

Use realistic tolerances that ensure functionality without overburdening production processes.