How to Design Sheet Metal Part in SolidWorks: Step-by-Step Guide

To design a sheet metal part in SolidWorks, start by creating a base feature using the Base Flange/Tab tool, then add bends and flanges with the Edge Flange and Bend tools. Use the Flatten feature to view the flat pattern for manufacturing.

Syntax

In SolidWorks, sheet metal design uses specific features and tools. The main commands are:

• Base Flange/Tab: Creates the initial sheet metal base from a sketch.
• Edge Flange: Adds flanges to edges of the base.
• Bend: Adds bends to existing edges.
• Flatten: Flattens the part to show the flat pattern for cutting.

Each tool requires a sketch or edge selection and parameters like thickness, bend radius, and angle.

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Base Flange/Tab: Select a 2D sketch > Sheet Metal > Base Flange/Tab > Set thickness and bend radius
Edge Flange: Select an edge > Sheet Metal > Edge Flange > Set flange length and angle
Bend: Select an edge > Sheet Metal > Bend > Set bend angle
Flatten: Sheet Metal > Flatten

Example

This example shows how to create a simple sheet metal box with a base and flanges:

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1. Create a new part in SolidWorks.
2. Sketch a rectangle on the Top Plane.
3. Use Sheet Metal > Base Flange/Tab, set thickness to 1.5mm, bend radius 3mm.
4. Select one edge of the base, use Sheet Metal > Edge Flange, set flange length 20mm, angle 90°.
5. Repeat Edge Flange on other edges as needed.
6. Use Sheet Metal > Flatten to see the flat pattern.

Output

A 3D sheet metal box with flanged edges and a flat pattern view showing the unfolded shape.

Common Pitfalls

• Not setting the correct sheet metal thickness before starting can cause errors in bends.
• Using non-closed sketches for the base flange will fail.
• Applying flanges on edges that are not straight or suitable can cause geometry errors.
• Forgetting to use the Flatten tool to check the flat pattern can lead to manufacturing issues.

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Wrong: Using an open sketch for Base Flange/Tab
Right: Always use a closed sketch for Base Flange/Tab

Quick Reference

Feature	Purpose	Key Parameters
Base Flange/Tab	Create base sheet metal part	Thickness, Bend Radius
Edge Flange	Add flanges to edges	Flange Length, Angle, Bend Radius
Bend	Add bends to edges	Bend Angle, Bend Radius
Flatten	View flat pattern	No parameters

Key Takeaways

Start sheet metal design with a closed sketch and Base Flange/Tab feature.

Set correct thickness and bend radius before adding flanges or bends.

Use Edge Flange to add flanges and Bend to create bends on edges.

Always check the flat pattern with Flatten to ensure manufacturability.

Avoid using open sketches or unsupported edges for sheet metal features.