The importance of design software in custom sheet metal fabrication
There are many design software packages available for custom design. Design software usually has full 3D capability with parts converted into flat profiles so that blanks can be produced correctly. However, it is important for the custom sheet metal fabrication shop to use similar software so that transfer between CAD packages will be accurate with no critical data lost. There are certain design considerations that must be taken into account to simplify fabrication and assembly.
- Bend radius can be achieved depending on the gauge of sheet metal. A thin metal sheet can be formed to a tight radius which is very difficult for a thicker sheet. It is also important to make allowances because the bend can have an effect on the overall part dimensions.
- When drafting 3D drawings, it is very easy to overlook clearances and interference fits. This can result into parts that do not fit during assembly particularly if the clearances are incorrect.
- Unless tight tolerances are actually required in the finished product, it is better to avoid not being tighter than necessary because it can significantly increase the costs of custom sheet metal fabrication.
- During design, it is important to ensure that entry holes, cut outs and other important items are positioned correctly because in most instances, these holes will be made prior to bending when the sheet is still flat.
- During assembly, components may be fastened together using bolts, rivets or welding and there must be provisions in designs for the fastening methods so that there will be adequate access to welding torches, wrenches or rivet guns.
- It is always important to ensure structural rigidity of the final component. If thin gauge metal sheet is used, it will have the tendency to flex unless it is suitably braced. On the other hand, heavy gauge metal sheet can be too rigid. If external loads will be imposed on the components, it is important to take into account the effect in structural rigidity when assembled.
- If components are difficult to fabricate and manufacture, they will certainly cost more. During design, it is critical to reduce the number of parts and to make them as simple as possible to be economically feasible.