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Originally Posted by s_forbes
I'd also love to hear more about some of the details that need to be considered when dealing with sheet metal design. One of the things I find most perplexing is the tolerances involved with these kind of parts... Some things I've read online mention that large sheet stock (like 4'x8') can vary in thickness as much as .005" (thicker in the middle).
Separately, how tight of tolerances can the machines hold? For example, when bending a c-channel out of 0.125 thick sheet, how much does the outside flange to flange distance vary?
It seems like getting rivet holes to line up would be a nightmare.
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These are the same things I have been wondering. I've heard from some teams that after they made their parts in sheet, the biggest challenge was making everything line up perfectly.