{"id":163080,"date":"2021-04-05T17:20:01","date_gmt":"2021-04-05T09:20:01","guid":{"rendered":"http:\/\/facfox.com\/docs\/?post_type=kb&#038;p=163080"},"modified":"2021-04-07T17:21:54","modified_gmt":"2021-04-07T09:21:54","slug":"design-guidelines-sheet-metal-fabrication","status":"publish","type":"kb","link":"https:\/\/facfox.com\/docs\/kb\/design-guidelines-sheet-metal-fabrication","title":{"rendered":"Design Guidelines: Sheet Metal Fabrication"},"content":{"rendered":"<p>Our basic guidelines for sheet metal fabrication include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.<\/p>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-12 column\">\n<div>\n<h2>Size<\/h2>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-8 column\">\n<div>\n<div class=\"tabs-container\">\n<h3>Maximum Dimensions<\/h3>\n<table class=\"protolabs-table\" border=\"0\" width=\"100%\">\n<tbody>\n<tr>\n<th><strong>SIZE<\/strong><\/th>\n<td>1,193.8mm x 3,022.6mm<\/td>\n<\/tr>\n<tr>\n<th>LENGTH<\/th>\n<td>3.048m<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>Minimum Dimensions<\/h3>\n<table class=\"protolabs-table\" border=\"0\" width=\"100%\">\n<tbody>\n<tr>\n<th><strong>FLAT PART<\/strong><\/th>\n<td>12.7mm x 12.7mm<\/td>\n<\/tr>\n<tr>\n<th>FORMED PART<\/th>\n<td>38.1mm x 38.1mm<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-12 column\">\n<div>\n<h2>Tolerances<\/h2>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-8 column\">\n<div>\n<div class=\"tabs-container\">\n<h3>Single Surface<\/h3>\n<table class=\"protolabs-table\" border=\"0\" width=\"100%\">\n<tbody>\n<tr>\n<th><strong>BENDS<\/strong><\/th>\n<td>+\/- 1 degree<\/td>\n<\/tr>\n<tr>\n<th><strong>OFFSETS<\/strong><\/th>\n<td>+\/- 0.304mm<\/td>\n<\/tr>\n<tr>\n<th><strong>HOLE DIAMETERS<\/strong><\/th>\n<td>+\/- 0.127mm<\/td>\n<\/tr>\n<tr>\n<th><strong>EDGE TO EDGE\/HOLE; HOLE TO HOLE<\/strong><\/th>\n<td>+\/- 0.127mm<\/td>\n<\/tr>\n<tr>\n<th><strong>HARDWARE TO EDGE\/HOLE<\/strong><\/th>\n<td>+\/- 0.254mm<\/td>\n<\/tr>\n<tr>\n<th><strong>HARDWARE TO HARDWARE<\/strong><\/th>\n<td>+\/- 0.381mm<\/td>\n<\/tr>\n<tr>\n<th><strong>BEND TO EDGE<\/strong><\/th>\n<td>+\/- 0.254mm<\/td>\n<\/tr>\n<tr>\n<th><strong>BEND TO HOLE\/HARDWARE\/BEND<\/strong><\/th>\n<td>+\/- 0.381mm<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>Multiple Surfaces<\/h3>\n<table class=\"protolabs-table\" border=\"0\" width=\"100%\">\n<tbody>\n<tr>\n<th>FEATURES SEPARATED BY TWO OR MORE BENDS<\/th>\n<td>+\/- 0.762mm<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-12 column\">\n<div>\n<h2>Materials<\/h2>\n<p><img fetchpriority=\"high\" decoding=\"async\" width=\"900\" height=\"400\" class=\"alignnone wp-image-163081 size-full\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication.png\" \/><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-4 column\">\n<div>\n<div>\n<ul>\n<li>Aluminum (1)<\/li>\n<li>Brass (2)<\/li>\n<li>Copper (3)<\/li>\n<li>Stainless Steel (4)<\/li>\n<li>Steel: CR Non-treated (5)<\/li>\n<li>Steel: CR Galvanneal and CR Galvanized (6)<\/li>\n<\/ul>\n<h2>Material Thickness<\/h2>\n<p>Because sheet metal parts are manufactured from a single sheet of metal, the part must maintain uniform wall thickness. Sheet metal thickness ranges from 0.024 in. (0.609mm) to 0.250 in. (6.35mm).<\/p>\n<table class=\"protolabs-table\" border=\"0\">\n<tbody>\n<tr>\n<th>GAUGE<\/th>\n<th colspan=\"3\">STEEL NON-ROHS COATED STEEL<\/th>\n<th colspan=\"3\">STAINLESS STEEL<\/th>\n<th colspan=\"2\">ALUMINUM<\/th>\n<th colspan=\"2\">COPPER<\/th>\n<th><strong>BRASS<\/strong><\/th>\n<\/tr>\n<tr>\n<td><strong> <\/strong><\/td>\n<td><strong>CRS<\/strong><\/td>\n<td><strong>Galvanneal<\/strong><\/td>\n<td><strong>Galvanized<\/strong><\/td>\n<td><strong>304-2B<\/strong><\/td>\n<td><strong>304 #4<\/strong><\/td>\n<td class=\"xl65\" width=\"64\" height=\"40\"><strong>316-2B<\/strong><\/td>\n<td class=\"xl65\" width=\"64\" height=\"40\"><strong>5052-H32<\/strong><\/td>\n<td><strong>6061-T6<\/strong><\/td>\n<td><strong>C101<\/strong><\/td>\n<td><strong>C110<\/strong><\/td>\n<td><strong>CDA260<\/strong><\/td>\n<\/tr>\n<tr>\n<td><strong> 24<\/strong><\/td>\n<td>0.6096<\/td>\n<td>0.6096<\/td>\n<td>0.6096<\/td>\n<td>0.6096<\/td>\n<td>0.6096<\/td>\n<td>0.6096<\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<\/tr>\n<tr>\n<td><strong> 22<\/strong><\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td>0.762<\/td>\n<td>0.762<\/td>\n<td>0.762<\/td>\n<td>0.635<\/td>\n<td>0.635<\/td>\n<td><\/td>\n<td><\/td>\n<td>0.635<\/td>\n<\/tr>\n<tr>\n<td><strong> 20<\/strong><\/td>\n<td>0.9144<\/td>\n<td>0.9144<\/td>\n<td>0.9144<\/td>\n<td>0.9144<\/td>\n<td>0.9144<\/td>\n<td>0.9144<\/td>\n<td>0.8128<\/td>\n<td>0.8128<\/td>\n<td>0.8128<\/td>\n<td>0.8128<\/td>\n<td>0.8128<\/td>\n<\/tr>\n<tr>\n<td><strong> 19<\/strong><\/td>\n<td>1.0668<\/td>\n<td><\/td>\n<td><\/td>\n<td>1.0668<\/td>\n<td>1.0668<\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td>1.016<\/td>\n<td>1.016<\/td>\n<td><\/td>\n<\/tr>\n<tr>\n<td><strong> 18<\/strong><\/td>\n<td>1.1938<\/td>\n<td>1.1938<\/td>\n<td>1.1938<\/td>\n<td>1.2192<\/td>\n<td>1.2192<\/td>\n<td>1.2192<\/td>\n<td>1.016<\/td>\n<td>1.016<\/td>\n<td>1.27<\/td>\n<td>1.27<\/td>\n<td>1.016<\/td>\n<\/tr>\n<tr>\n<td><strong> 16<\/strong><\/td>\n<td>1.4986<\/td>\n<td>1.4986<\/td>\n<td>1.4986<\/td>\n<td>1.4986<\/td>\n<td>1.4986<\/td>\n<td>1.4986<\/td>\n<td>1.27<\/td>\n<td>1.27<\/td>\n<td>1.6002<\/td>\n<td>1.6002<\/td>\n<td>1.27<\/td>\n<\/tr>\n<tr>\n<td><strong> 14<\/strong><\/td>\n<td>1.8796<\/td>\n<td>1.8796<\/td>\n<td>1.8796<\/td>\n<td>1.8796<\/td>\n<td>1.8796<\/td>\n<td>1.8796<\/td>\n<td>1.6002<\/td>\n<td>1.6002<\/td>\n<td><\/td>\n<td>2.032<\/td>\n<td>1.6002<\/td>\n<\/tr>\n<tr>\n<td><strong> 13<\/strong><\/td>\n<td>2.2606<\/td>\n<td>2.2606<\/td>\n<td>2.2606<\/td>\n<td>2.2606<\/td>\n<td>2.2606<\/td>\n<td>2.2606<\/td>\n<td><\/td>\n<td><\/td>\n<td>2.286<\/td>\n<td>2.286<\/td>\n<td><\/td>\n<\/tr>\n<tr>\n<td><strong> 12<\/strong><\/td>\n<td>2.6416<\/td>\n<td>2.6416<\/td>\n<td>2.6416<\/td>\n<td>2.6416<\/td>\n<td>2.6416<\/td>\n<td>2.6416<\/td>\n<td>2.032<\/td>\n<td>2.032<\/td>\n<td><\/td>\n<td><\/td>\n<td>2.032<\/td>\n<\/tr>\n<tr>\n<td><strong> 11<\/strong><\/td>\n<td>3.0226<\/td>\n<td>3.0226<\/td>\n<td>3.0226<\/td>\n<td>3.0226<\/td>\n<td>3.0226<\/td>\n<td>3.0226<\/td>\n<td>2.286<\/td>\n<td>2.286<\/td>\n<td>3.175<\/td>\n<td>3.175<\/td>\n<td>2.286<\/td>\n<\/tr>\n<tr>\n<td><strong> 10<\/strong><\/td>\n<td>3.4036<\/td>\n<td>3.4036<\/td>\n<td>3.4036<\/td>\n<td>3.4036<\/td>\n<td><\/td>\n<td>3.4036<\/td>\n<td>2.54<\/td>\n<td>2.54<\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<\/tr>\n<tr>\n<td><strong> 8<\/strong><\/td>\n<td>4.064<\/td>\n<td><\/td>\n<td><\/td>\n<td>4.064<\/td>\n<td><\/td>\n<td><\/td>\n<td>3.175<\/td>\n<td>3.175<\/td>\n<td><\/td>\n<td><\/td>\n<td>3.175<\/td>\n<\/tr>\n<tr>\n<td><strong>7<\/strong><\/td>\n<td>4.5466<\/td>\n<td><\/td>\n<td><\/td>\n<td>4.5466<\/td>\n<td><\/td>\n<td><\/td>\n<td>4.064<\/td>\n<td>4.064<\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<\/tr>\n<tr>\n<td><strong>3<\/strong><\/td>\n<td>6.35<\/td>\n<td><\/td>\n<td><\/td>\n<td>6.35<\/td>\n<td><\/td>\n<td><\/td>\n<td>4.826<\/td>\n<td>4.826<\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<\/tr>\n<tr>\n<td><strong>2<\/strong><\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<td>6.35<\/td>\n<td>6.35<\/td>\n<td><\/td>\n<td><\/td>\n<td><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<figure id=\"attachment_163082\" aria-describedby=\"caption-attachment-163082\" style=\"width: 570px\" class=\"wp-caption aligncenter\"><img decoding=\"async\" class=\"wp-image-163082 size-full\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-1.png\" alt=\"\" width=\"570\" height=\"308\" \/><figcaption id=\"caption-attachment-163082\" class=\"wp-caption-text\">Because sheet metal parts are manufactured from a single sheet of metal, the part must maintain uniform wall thickness.<\/figcaption><\/figure>\n<figure id=\"attachment_163083\" aria-describedby=\"caption-attachment-163083\" style=\"width: 570px\" class=\"wp-caption aligncenter\"><img decoding=\"async\" class=\"wp-image-163083 size-full\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-2.png\" alt=\"\" width=\"570\" height=\"308\" \/><figcaption id=\"caption-attachment-163083\" class=\"wp-caption-text\">Sheet metal thickness ranges from 0.024 in. (0.609mm) to 0.138 in. (3.505mm).<\/figcaption><\/figure>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-12 column\">\n<div>\n<h2>Finishing<\/h2>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<div>\n<div class=\"container\">\n<div class=\"row clearfix\">\n<div class=\"col-md-8 column\">\n<div>\n<p>We offer welded assemblies, standard mill, edge breaking, and orbital-sanded surface finishes along with a number of additional sheet metal finishing options:<\/p>\n<ul>\n<li><strong>Seam, tack, <\/strong>and<strong> stitch welding<\/strong><\/li>\n<li><strong> Hardware insertion <\/strong>and<strong> riveting:<\/strong> Standard PEM sheet metal hardware<\/li>\n<li><strong>Powder coating<\/strong>: A variety of powder coat paint colors available in textured and non-textured finish, including RAL colors. <a title=\"Colors\" href=\"https:\/\/www.protolabs.com\/materials\/colors\/?service=sheetMetalFabrication\" target=\"_blank\" rel=\"noopener\" data-udi=\"umb:\/\/document\/7a678acba9954520ac960343d919f285\" data-anchor=\"?service=sheetMetalFabrication\">View our powder coat options here<\/a><\/li>\n<li><strong>Silk screening <\/strong>(one- and two-color): Colors mixed to closely match most Pantone numbers<\/li>\n<li><strong>Assemblies<\/strong>: POP-riveted and welded<\/li>\n<li><strong>Plating<\/strong>: Anodize, chromate, zinc, and passivate<\/li>\n<\/ul>\n<h2>Bend Radius<\/h2>\n<p>We hold a +\/- 1 degree tolerance on all bend angles. We offer a wide range of common bend radii, but our standard bend radius is 0.030 in (0.762mm). This is an industry standard and the most cost-effective. Flange length must be at least 4 times the material thickness.<\/p>\n<p>It is recommended to use the same radii across all bends, and flange length must be at least 4 times the material thickness.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" width=\"570\" height=\"308\" class=\"wp-image-163084 size-full aligncenter\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-3.png\" \/><\/p>\n<h2>Hems<\/h2>\n<p>We form both open and closed hems. The tolerance of a hem is dependent upon the hem\u2019s radius, material thickness, and features near the hem.<\/p>\n<p>We recommend that the minimum inside diameter equals the material thickness, and a hem return length of 6x material thickness.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" width=\"570\" height=\"308\" class=\"wp-image-163085 size-full aligncenter\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-4.png\" \/><\/p>\n<h2>Offsets<\/h2>\n<p>Offsets are used to create Z-shaped profiles in sheet metal parts. We offset height tolerance at +\/-0.012 in.  (0.304mm) from top of sheet to top of form and recommend an offset of 0.030 in. (0.762mm).<\/p>\n<p>Additional standard options include: available 0.060 in. (1.524mm), 0.093 in. (2.362mm), 0.125 in. (3.175mm), 0.187 in. (4.749mm), 0.213 in. (5.410mm), 0.250 in. (6.35mm), 0.281 in. (7.137mm), and 0.312 in. (7.924mm).<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" width=\"570\" height=\"308\" class=\"wp-image-163086 size-full aligncenter\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-5.png\" \/><\/p>\n<h2>Holes and Slots<\/h2>\n<p>Holes and slots should be a minimum of material thickness in diameter. If material is 0.036 in. (0.914mm) or thinner, the hole should be 0.062 in. (1.574mm) from the material edge; if the material is thicker than 0.036 in. (0.914mm), the hole should be at least 0.125 in. (3.175mm) from the material edge to avoid distortion. If hardware inserts are required, the spacing should be according to the manufacturer\u2019s specifications.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" width=\"570\" height=\"308\" class=\"wp-image-163087 size-full aligncenter\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-6.png\" \/><\/p>\n<h2>Notches and Tabs<\/h2>\n<p>Notches must be at least the material\u2019s thickness or 0.04 in. (1.016mm), whichever is greater, and can be no longer than 5 times its width. Tabs must be at least 2 times the material\u2019s thickness or 0.126 in. (3.200mm), whichever is greater, and can be no longer than 5 times its width.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" width=\"570\" height=\"308\" class=\"wp-image-163088 size-full aligncenter\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-7.png\" \/><\/p>\n<h2>Countersinks<\/h2>\n<p>We offer both machined and formed countersinks\u2014conical holes cut into a manufactured object allowing a screw, nail, or bolt to be inserted flush with the surface.<\/p>\n<p>We recommend the major diameters of countersinks measure between 0.090 in. (2.286mm) and 0.500 in. (12.7mm) using one of the following standard angles: 82\u00b0, 90\u00b0, 100\u00b0, and 120\u00b0.<\/p>\n<p>Tolerance for formed countersink major diameter is +\/- 0.010 in. (0.254mm).<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" width=\"570\" height=\"308\" class=\"wp-image-163089 size-full aligncenter\" src=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication-8.png\" \/><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Our basic guidelines for sheet metal fabrication include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time. Size Maximum Dimensions SIZE 1,193.8mm x 3,022.6mm LENGTH 3.048m Minimum Dimensions FLAT PART 12.7mm x 12.7mm FORMED PART 38.1mm x 38.1mm Tolerances Single Surface BENDS +\/- 1 degree OFFSETS +\/- 0.304mm [&hellip;]<\/p>\n","protected":false},"author":4,"featured_media":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"kbtopic":[47],"kbtag":[39,509,498],"class_list":["post-163080","kb","type-kb","status-publish","hentry","kbtopic-design","kbtag-design","kbtag-metal-fabrication","kbtag-sheet-metal"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v27.4 (Yoast SEO v27.4) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Design Guidelines: Sheet Metal Fabrication - FacFox Docs<\/title>\n<meta name=\"description\" content=\"Our basic guidelines for sheet metal fabrication include important design considerations to help improve part manufacturability, enhance cosmetic Our basic guidelines for sheet metal fabrication include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/facfox.com\/docs\/kb\/design-guidelines-sheet-metal-fabrication\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Design Guidelines: Sheet Metal Fabrication\" \/>\n<meta property=\"og:description\" content=\"Our basic guidelines for sheet metal fabrication include important design considerations to help improve part manufacturability, enhance cosmetic Our basic guidelines for sheet metal fabrication include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/facfox.com\/docs\/kb\/design-guidelines-sheet-metal-fabrication\" \/>\n<meta property=\"og:site_name\" content=\"FacFox Docs\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/facebook.com\/facfox3d\" \/>\n<meta property=\"article:modified_time\" content=\"2021-04-07T09:21:54+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/facfox.com\/docs\/wp-content\/uploads\/2021\/04\/Pasted-into-Design-Guidelines-Sheet-Metal-Fabrication.png\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:site\" content=\"@facfox3d\" \/>\n<meta name=\"twitter:label1\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"3 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/facfox.com\\\/docs\\\/kb\\\/design-guidelines-sheet-metal-fabrication\",\"url\":\"https:\\\/\\\/facfox.com\\\/docs\\\/kb\\\/design-guidelines-sheet-metal-fabrication\",\"name\":\"Design Guidelines: Sheet Metal Fabrication - 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