Customers frequently ask questions about sheet metal design, materials, finishes and manufacturing techniques. In Design Tips and Materials and Finishes we address many of these issues and further topics are discussed below.
Producing sheet metal parts with large radii
Answer
A large radius in this sense is one greater than can be formed using standard pressbrake tooling, typically 3mm. Above this, a radius can be formed by manufacturing special tooling, by approximating the radius with progressive folds on a pressbrake or by rolling the radius on a rolling machine.
Scratch free sheet metal components
Answer
Aluminium and stainless steel can be purchased with a plastic peelable polycoat film on one or both sides eliminating scratching. Mild steel, zintec and galvanised steel sheet cannot be supplied with polycoat and to minimise scratching here, both our Amada CNC punching machines have brush beds.
Welding Studs & Stand-offs without witness marks
Answer
Self clinching press-in studs or stand-offs leave witness marks on the front face of panels after powder coating which can be unsightly. If wet spraying, these witness marks can be filled but this is time consuming. An alternative is to ‘studweld’ on the back face of the panel. If the position of the studs has to be accurate, a customised jig is normally required which is expensive. A cost effective alternative is to use custom made plastic stick-on labels with text and logos to cover up witness marks which also eliminates the need for silkscreen printing.
3D Modelling Systems
Answer
We use both Solidworks and Inventor for 3D modelling. These systems are very important to us because they have in-built facilities for sheet metal modelling and flat pattern development. We have no particular preference and their facilities are much the same. We tend to use Solidworks more because it is used by the majority of our customers.
