[JCharlton]

Our team has started using sheet metal in several areas of our robot, and my students are starting to see the benefits of lighter weight, faster build, and more than adequate strength. Cosmetically our robots are looking better, and we reduce the cost of using extrusion.

We use Inventor to design, but also a lot of measure/bend/cut to fit. Despite being a Mech Eng there's a LOT I don't know about sheet metal standards and building, hasn't stopped me from trying.

The best exercise is to make things out of stiff cardboard and staples. Anything you can staple you can punch a hole and avoid drilling (look into getting a Roper Whitney punch). Also a pneumatic rivet gun makes everyone happy.

Good luck!