Design Element | Suggestions (Industry Standard Values) | Reasons and Benefits |
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Material Thickness | Recommended range: 0.5 - 12 mm (typical: 1 - 6 mm) | Ensures optimal bend accuracy, reduces tool wear, and minimizes defects. |
Minimum Bend Radius | Minimum radius ≥ 1x to 1.5x material thickness | Reduces cracking risk, maintains structural integrity, and prevents distortion. |
Bend Allowance | Calculate based on material thickness and bend radius | Ensures dimensional accuracy after bending, compensating for material stretch/compression. |
Minimum Flange Length | ≥ 4x material thickness (ideal ≥ 6x thickness) | Provides adequate surface area for proper bending and stable tooling. |
Hole Distance from Bend Line | Minimum distance ≥ 2 - 3x material thickness | Prevents hole deformation or stretching during bending. |
Hole Diameter | Hole diameter ≥ material thickness | Prevents hole distortion, maintains accuracy, and preserves structural integrity. |
Bend Angles | Typical angles ≤ 120° without special tooling | Ensures high accuracy and consistent quality, reducing special tool requirements. |
Edge-to-Bend Distance | Minimum ≥ 2x material thickness | Prevents edge deformation, maintains part stability, and ensures high-quality bends. |
Tolerances | Typical linear tolerance: ±0.2 - 0.5 mm | Reflects achievable accuracy in bending, balancing precision and cost-effectiveness. |
Relief Cuts | Use relief cuts near complex bends | Reduces material stress, prevents tearing/cracking, and allows complex shapes. |
Material Grain Direction | Bend perpendicular (90°) to grain when possible | Minimizes cracking, improves bend quality, and ensures long-term durability. |
U-shaped Channel Width | Width ≥ 2x depth recommended | Ensures proper bending tool clearance, avoids deformation, and maintains accuracy. |
Text and Logos | Locate text away from bend areas by ≥ 3 mm | Prevents distortion of engraved or laser-marked text during bending. |