Designing for Manufacturability: Avoiding Common Sheet Metal Pitfalls

Smart design decisions can make or break your sheet metal projects. When manufacturing costs spiral or production delays mount, the root cause often traces back to design choices made at the very beginning. Let's explore how to create sheet metal designs that not only look good on paper but also translate efficiently to the production floor.

Sheet Metal Design Sep 4, 2025 0 22 Add to Reading List

Designing for Manufacturability: Avoiding Common Sheet Metal Pitfalls

Why Design for Manufacturability Matters

The Hidden Costs of Poor Design

Up to 70% of product costs are determined during the design phase
Redesigns and engineering change orders delay projects by 4–8 weeks
Material waste from improper specifications increases costs by 15–25%

When designers understand manufacturing constraints, they create components that require fewer specialized operations and minimize material waste—directly impacting your bottom line.

Common Sheet Metal Design Mistakes

Insufficient Bend Relief

Without proper relief cuts, material tears at bends and corners deform. Always provide relief proportional to material thickness — typically 1–1.5× the thickness.

Holes Too Close to Bends

Placing holes closer than 2× material thickness from a bend can cause distortion. The metal stretches during bending, pulling holes out of shape or specification.

Overly Tight Tolerances

Specifying unnecessarily tight tolerances (below ±0.005") drives up costs dramatically. Standard sheet metal processes typically achieve ±0.010" to ±0.030" economically.

Working with experienced manufacturers like Consac early in your design process helps identify these issues before they become expensive problems. Prevention costs far less than correction.

Practical Design Guidelines

Material Selection Considerations

Choose materials based on both function and manufacturability:
- Standard gauges cost less and have better availability than custom thicknesses
- Material properties affect minimum bend radii—aluminum requires larger radii than steel
- Surface treatments should be specified early as they influence material choice and tolerances
When designing parts that will be powder coated, remember to account for coating thickness in your tolerance calculations

Design for Assembly Strategies

Minimize Part Count

Combine features into single parts when possible. Every additional component increases assembly time, inventory management, and potential failure points.

Standardize Fasteners

Use the same screw sizes throughout your design. This reduces tool changes during assembly and simplifies inventory management.

Design for One-Way Assembly

Create asymmetrical features that prevent incorrect installation. Self-aligning components reduce assembly errors by up to 70%.

Ensure Tool Access

Provide sufficient clearance for tools during assembly. Hidden fasteners may look cleaner but dramatically increase assembly time and cost.

Taking Action: Next Steps for Better Designs

Key Takeaways

Start with manufacturing input at the design phase
Design with standard materials and processes in mind
Create detailed specifications but avoid unnecessarily tight tolerances
Account for bending effects on material dimensions and hole positions
Consider how your design will be assembled and serviced

Remember: Design changes become exponentially more expensive as a project progresses. Early attention to manufacturability pays dividends throughout the product lifecycle.

Pro Tip

Create a manufacturing review checklist specific to your common projects. Include items like minimum bend radius, hole-to-edge distances, and standard fastener specifications