What things should my team keep in mind when designing sheet metal parts?

[tahmid0517]

My team recently got a sheet metal sponsor this year and we're going to be working with them during the 2016 season. We've never designed sheet metal parts for our robot before, so for those of you that have, what things should my team keep in mind when designing them?

[GeeTwo]

Not having faced this question myself :envy:*, I suggest that you learn from your sponsor what exactly their capabilities are, and what metals (including grades) they use. I suspect that a sheet metal sponsor will have plenty of 5052 aluminum, as it has rather high tensile strength and is great for sheet-metal brake-bending applications.

Find out what thicknesses and metal grades they keep in stock, and how much angle they're willing to bend (most bends are 90 degrees or less), and how well they can handle different bends of short/interrupted segments (show them the inner plate of a 2014U2 as an example). It's probably better to design a part that they can fabricate in three days from in-house stock than a part that needs three weeks because they have to order stock, even if it comes out a few ounces heavier. Then, remember to design around what they have told you that they can build!


* another emoji that ought to exist, with bright green eyes

[DonRotolo]

The big thing with sheet metal is that bends do not consume ZERO space. Unlike bending a sheet of paper, if you don't account for the bend distance, all your measurements will be off.

The advice above is good: Go speak with them, bring students.

Then, build a simple bracket of some type, one with a few holes that need to line up and some bends, design it, and have the sponsor fab it. Then, compare what you got with what you expected.

You might also ask to borrow a real item they made, and compare it to the drawings, to pick up the little tricks used by professionals. For instance:

• A row of small holes makes a bend come out sharper and with less effort, good for long bends.
• Beading stiffens flat panels
• Stiffer still are flanges