Last updated on December 1st, 2023 at 01:11 pm
Want to save time and money on your next sheet metal prototype?
At Approved Sheet Metal, we have decades of experience helping our customers transform their brilliant ideas into physical sheet metal prototypes.
We’ve used our expertise to develop a Sheet Metal Fabrication Design for Manufacturing (DFM) eBook, which includes all the best tips we've accumulated over the years.
You'll need to download the eBook for the full set of tips, but we're excited to give you a sneak peek at a few of them in today's blog.
Table of Contents
- 1 3 DFM Tips for Sheet Metal Prototypes
- 2 Rapid Sheet Metal DFM FAQ
- 2.0.1 What is the purpose of the Sheet Metal Fabrication Design for Manufacturing (DFM) eBook offered by Approved Sheet Metal?
- 2.0.2 What should I consider regarding uniform wall thickness in my sheet metal prototype design?
- 2.0.3 What guidelines should I follow when incorporating notches and tabs into my sheet metal prototype design?
- 2.0.4 How will my fabricator decide whether to use a drill press or punch press tooling for countersinks in my sheet metal prototype design?
- 2.0.5 How can I access the full set of DFM tips for sheet metal prototypes mentioned in the eBook preview?
3 DFM Tips for Sheet Metal Prototypes
1. Ensure uniform wall thickness
Keep in mind that your sheet metal shop will fabricate your sheet metal prototype from a single piece of material with uniform thickness throughout. We use materials that are a minimum of 0.010” to 0.25” thick.
If you have a complex design, we can help you explore options such as cutting shapes completely through the material or post-machining the material to the desired shape.
2. Follow strict dimensional guidelines for notches and tabs
If you’re including notches or tabs in your design, follow these guidelines to ensure that your sheet metal prototype can withstand external tensile and flexural forces:
Notches must be at least the material’s thickness or 0.04”, whichever is greater, and should be no longer than 5x the width of the material
Tabs must be at least 2x the material’s thickness or 0.126”, whichever is greater, and should be no longer than 5x the width of the material
3. Know how countersinks are applied
When designing countersinks into a sheet metal prototype, keep in mind that there are only two ways countersinks can be applied: via drill press or punch press tooling.
To determine which method is best for your sheet metal prototype, consider your part geometry. If your part has tight angles or features that are difficult to reach with tooling, we’ll likely need to use a drill press. Otherwise, punch press tooling is likely to be the easiest option.
If you have additional DFM questions about your sheet metal prototype, feel free to request a quote quickly and easily on our website. We’ll respond ASAP to discuss the best approach to your part.
Rapid Sheet Metal DFM FAQ
Our DFM eBook is a valuable resource containing expert tips and insights for optimizing the design of sheet metal prototypes. It helps you make the most of your sheet metal fabrication project by ensuring cost-effective and efficient production.
Your sheet metal prototype should have a uniform wall thickness. Our shop typically works with materials ranging from 0.010” to 0.25” thick. If your design is complex, we can assist by suggesting alternatives like cutting shapes through the material or post-machining to achieve the desired shape.
For notches in your design, they should be at least the material’s thickness or 0.04”, whichever is greater, and no longer than 5x the width of the material. Tabs should be at least 2x the material’s thickness or 0.126”, whichever is greater, and should also be no longer than 5x the width of the material. These guidelines ensure your prototype can withstand external tensile and flexural forces.
The choice between drill press or punch press tooling for countersinks depends on your part's geometry. If your part has tight angles or features that are difficult to reach with tooling, a drill press may be required. Otherwise, punch press tooling is often the more straightforward option. We can help you determine which method is best for your specific sheet metal prototype.
To access the complete set of DFM tips for sheet metal prototypes, you can download our Sheet Metal Fabrication Design for Manufacturing (DFM) eBook, which includes all the best practices we've gathered over the years. It's a valuable resource for optimizing your sheet metal design and fabrication process.
