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

[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