Sheet metal fabrication

Flat sheet is cut (by laser, punch or waterjet) and bent on a press brake, then joined with fasteners, rivets, welds or self-clinching hardware. It is the backbone of electrical enclosures, equipment chassis, brackets and HVAC components. At high volumes, progressive stamping dies replace cutting and bending with very low per-part cost but significant tooling.

Design rules come from the shop's tooling: inside bend radius relative to material thickness, minimum flange length, minimum distance from holes to bends, and relief cuts at corners. Designing to a supplier's standard bend tooling keeps cost down.

Where it bites: tolerances accumulate across several bends, cosmetic finishes (powder coat, anodizing, brushing) add cost and lead time, and welded assemblies can distort.