When designing an enclosure, panel, or part, you have many design aspects that need to be taken into consideration, in addition to all of your requirements. It can be difficult to manage everything you need to keep track of, especially if you are new to the world of custom manufacturing. To ensure that you get the final part that suits your project requirements, you should avoid sheet metal design mistakes, which we have outlined in this blog.

We'll go into 4 typical design errors in this post and discuss how to avoid them so that your sheet metal design produces better outcomes.

4 Common Sheet Metal Design Mistakes

Though you can observe various design errors in sheet metal design, here are 4 most common yet critical mistakes in sheet metal design.

1) Not Choosing Materials Carefully

The selection of the appropriate material is one of the most important parts of sheet metal manufacturing. Every material has special qualities that impact both the production process and the quality of finished goods. Some of the most common materials include carbon steel, stainless steel, and aluminium, and each has its strengths and weaknesses.

Why it is a mistake:

• Levels of malleability, strength, and corrosion resistance differ among materials.
• Incorrect material selection can cause cracking, warping, or early wear and tear, reducing the product's durability.

Tips to avoid:

• Consider the usage, application, and surrounding environment in which the product will be used.
• Consult with your supplier or a materials expert to understand the best options for your specific needs. 
• Perform thorough tests and develop prototypes before committing to large-scale manufacturing.

2) Ignoring Bend Radius Guidelines 

The inside curvature of a bending in sheet metal is referred to as the bend radius. To prevent breaking or deformation of the sheet metal, a minimum bend radius must be maintained for every material. Neglecting the recommended rules can lead to structural deformation, fitment issues, and poor product performance.

Why it is a mistake:

• A wrong bend radius can weaken the metal and result in stress fractures.
• Because of the greater scrap rates and rework, it increases production costs.

Tips to avoid:

Follow the bend radius instructions specified by the manufacturer for the material.

Use software programs that can simulate the bending process and highlight any problems.

3) Overlooking Tolerances and Clearances

In sheet metal design, tolerances and clearances are essential. They define the fitment with counterpart and overall functionality. Avoiding these results in functional failure and assembly-related issues.

Why it is a mistake:

• Improper tolerances result in fitment problems, which delay assembly and cause rework and rejections.
• Inadequate clearances cause friction between components. This increases premature wear and tear of materials, resulting in shorter product life.

Tips to avoid:

• During the design stage, incorporate precise clearances and tolerances.
• Apply methods and technologies for precise measurement to guarantee compliance during production.
• Take regular reviews of and updates to your tolerance standards in response to input from end users and the production floor.

4) Ignoring the Manufacturing Process

There are several sheet metal manufacturing processes, such as cutting, bending, punching, and welding. Lack of consideration for these procedures can result in impracticality and cost.

Why it is a mistake:

• Non-manufacturable designs can lead to significant cost overruns and major delays.
• Redesigns, more expensive tools, and waste of materials could result from it.

Tips to avoid:

• Early in the design phase, collaborate with the manufacturing team to understand the processes.
• Create easier-to-manufacture designs by applying design-for-manufacturability (DFM) concepts.
• Keep yourself updated about the latest fabrication techniques and technologies to guarantee the viability and economy of your designs.

By avoiding these typical sheet metal manufacturing errors, you can save yourself time and money. By considering material choice, bend radius, tolerances, and the manufacturing process, you can produce better designs that satisfy the project needs and run for a longer time. Careful preparation, collaborative teamwork, and acute attention to detail are essential to effective sheet metal production.

Mech Power offers sheet metal and structural fabrication services to various businesses and individuals. We have a wide range of capabilities, cutting-edge methods, and top-notch machines and tools that allow us to provide end-to-end solutions to multiple customers.

Contact us if you have any questions about the design of your next project. And now you can directly place an inquiry for the sheet metal through our website.