Creating Sheet Metal Parts from Thickened Surfaces

[Malcolm Crowe]

Occasionally we need to model sheet metal parts where the standard sheet metal tools aren't able to provide us with the desired end result. On these occasions we use a technique based around the following:

1. Structured Part Mode (to keep all of the construction elements associated inside the part)

2. Surface Tools (driven by 2D sketches)

3. Thickening Tool

In the attached image and video, the sheet metal panel is made up of 3 vertical sections. These sections then have horizontal bends at different angles that then need to meet together (with a gap).

It takes a bit of practice regarding understanding how "Structured" models work, and how best to implement the principle of this technique, but you end up with adjustable parametric models.

When the model is complete, you can then create the flat pattern simply using the "Solid/Surface Flat Pattern from Faces" tool.

Malcolm

Edited March 11, 2023 by Malcolm Crowe

[Cary OConnor]

Nice Tip! 

Can you upload the file as well? It would be a good reference model.

Thanks

Cary

[Malcolm Crowe]

File attached.

IRONCAD 2019 PU1.1 - Sheet Metal Part from Thickened Surfaces.ics

[Cary OConnor]

Thanks. 

You can also use the Convert to Sheet Metal Part which will create a sheet metal part with Sketch Bend lines if you want to edit that shape more using the sheet metal native tools.

Best Regards,

Cary

[HDEAR]

On 9/7/2019 at 8:39 AM, Cary OConnor said:

Thanks. 

You can also use the Convert to Sheet Metal Part which will create a sheet metal part with Sketch Bend lines if you want to edit that shape more using the sheet metal native tools.

Best Regards,

Cary

I liked Malcolm's approach to difficult sheet metal shape problem solving and am keen to learn more about structured parts vs innovative but that's another story.

The convert to sheet metal part you mention above struck problems when trying to make the part in the same thickness as Malcolm's solid model - 6mm. Anything above 2.5mm thick gave grief as shown in attachments. It seems one bend plane was a simple radiused bend whereas the other bend plane seemed multiple small bend radii. I imagine you'd have to take this into consideration when designing the structured part if you wanted to use the  Convert to Sheet Metal Part ???

[Malcolm Crowe]

For those interested, the attached video is another example of sheet metal parts created by first creating trimmed surfaces (within a structured part), followed by using the Thickening Tool.

Malcolm