pic: 4587-Sheet Metal Chassis

[Cash4587]

Originally Posted by Joe G.

If this is your first time with sheet metal, definitely talk to your sponsor and find out what bend radius they recommend for a given thickness, as this will be driven by the tooling they use. Usually not a huge deal, but updating this after the fact can be somewhat hairy on complex structures depending on how you define your flanges.

Right now, your radii look far larger than what I typically see used for .090" Aluminum, although 6061 vs. 5052 would call for a larger bend radius. Generally, 5052 is recommended for sheet metal work, but some teams do use bent 6061.

The sponsor my team has does use a .25 bend radius for .090" 6061 T6 it does seem big but that's what they call for for 90* bends. Other angles will be different though with BD and BR I just haven't put those in.