A sheet enclosure begins as a flat pattern but succeeds as a three-dimensional assembly. Bend radii, flange lengths, corner reliefs, hardware access, seams, and finish all interact. Before releasing a sheet metal housing, designers should mentally walk through cutting, bending, joining, and final assembly. CSMolding's fabrication service includes cutting, press-brake forming, stamping, joining, and finishing, so a manufacturable design is one that gives each step enough room to do its job.

Build around bends, not after them

Sheet does not fold along a mathematically sharp line. Every bend has an inside radius and consumes material through the bend zone. That is why flat-pattern calculations use bend allowance or bend deduction. If the CAD system uses the wrong material thickness, radius, or K-factor assumptions, hole positions and overall dimensions can shift after forming.

Keep holes and slots away from bend zones when possible. Features placed too close can stretch or distort during forming. Where a cutout must approach a bend, discuss relief geometry and tooling limits with the fabricator.