At AS Prototypes, we partner with product engineers and designers globally to develop sheet metal prototypes, ranging from single pieces to large-scale productions up to 100,000 units. Our specialties include assemblies, brackets, enclosures, housings, and cabinets. Our in-house experts ensure timely and cost-effective delivery, and we offer advice to optimize sheet metal part production and reduce expenses. Here are some key strategies to consider for designing your sheet metal parts for more efficient fabrication:
Hole Size:
- The diameter of any holes should be no less than the thickness of the sheet metal to avoid damage or tool breakage, which helps in saving production time and costs.
- Use consistent hole sizing across the prototype to reduce the need for changing tools frequently.
- Keep holes at least six times the material’s thickness away from bends to preserve the structural integrity of the part.
Bend Radius:
- Use a consistent bend radius throughout the part to simplify production and decrease labor time. The ideal inner radius should be equivalent to the thickness of the sheet metal to avoid undue stress on the material.
- Opt for larger radii where possible to enhance the durability and integrity of the finished product.
Bend Orientation:
- Design all bends to go in the same direction to facilitate manufacturing. This approach helps save time and costs by minimizing the need to reorient the part during production.
Hems:
- Design your sheet metal prototypes with hems to safeguard the edges of the metal sheet. Prefer teardrop or open hems over flat hems to reduce the risk of material fractures.
For additional guidance on sheet metal prototyping design, our specialists at AS Prototypes are ready to assist. Reach out today for a free product review and consultation to ensure your project’s success.
