90% of Sheet Metal Problems Start in the Design Stage

From real production experience, most sheet metal issues are not caused by manufacturing, but by design decisions made early on.

Here are some common design mistakes we see repeatedly:

1️⃣ Zero bend radius

In real fabrication, a bend radius can never be zero.
Minimum bend radius depends on material type and thickness, and ignoring this often causes cracking or deformation.

2️⃣ Holes too close to bend lines

Holes or slots placed too close to a bend line may lead to:

• Distortion
• Cracking
• Unstable dimensions

3️⃣ No consideration for assembly sequence

A part may look fine in CAD, but once bent:

• Tools cannot reach
• Parts cannot be assembled
• Welding becomes impossible

📌 Design tip:
When designing sheet metal parts, always ask:
👉 “How will this part actually be manufactured step by step?”

💬 Discussion:
What is the biggest sheet metal design mistake you've made or seen?
Bend issues, tolerances, or assembly problems?

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