Sheet metal cut features in Solidworks - Step-by-Step Guide

Introduction

Sheet metal cut features let you remove parts of a metal sheet in your design. This helps create holes, slots, or shapes needed for your metal part. It solves the problem of shaping metal sheets without complex machining.

When you need to add holes for screws or bolts in a metal panel

When creating slots for ventilation or wiring in a metal enclosure

When cutting out shapes to reduce weight in a metal bracket

When designing tabs or notches to help bend or assemble sheet metal parts

When removing excess metal to fit parts together in an assembly

Steps

Step 1: Click

- Sheet Metal tab

The sheet metal tools appear in the toolbar

Step 2: Select

- Cut-Extrude feature

The Cut-Extrude property manager opens on the right side

Step 3: Draw

- Sketch on the sheet metal face

A closed shape appears on the metal sheet where you want to cut

Step 4: Set

- Cut-Extrude depth

The cut depth is defined to go through the sheet metal thickness

Step 5: Click

- OK button in Cut-Extrude property manager

The cut feature removes the metal inside the sketch shape

Before vs After

Before

A flat sheet metal face with no holes or cutouts

After

The sheet metal face has a clean hole or slot cut through it matching the sketch shape

Settings Reference

Cut-Extrude Depth

📍 Cut-Extrude property manager

Defines how deep the cut goes into the sheet metal

Default: Through All

Direction

📍 Cut-Extrude property manager

Controls the direction the cut is applied relative to the sketch plane

Default: One Direction

Sheet Metal Parameters

📍 Sheet Metal tab > Sheet Metal Parameters

Defines the thickness and bend radius used for cut depth and bends

Default: User defined thickness and bend radius

Common Mistakes

Cut depth is set too shallow and does not go through the sheet metal

The cut will not remove the metal fully, leaving unwanted material

Set cut depth to 'Through All' or a depth equal to or greater than sheet thickness

Sketch is not closed before creating the cut

Cut-Extrude requires a closed sketch to define the cut area

Ensure the sketch is fully closed with no gaps before applying the cut

Cut direction is opposite to the sheet metal face

Cut may remove material from the wrong side or not at all

Check and set the cut direction correctly in the property manager

Summary

Sheet metal cut features remove metal by cutting shapes on sheet faces

Use Cut-Extrude with a closed sketch and proper depth to create holes or slots

Always verify cut direction and depth to avoid incomplete or wrong cuts

Practice

1. What is the main purpose of sheet metal cut features in SolidWorks?

easy

A. To remove material and create holes or shapes in sheet metal parts

B. To add thickness to sheet metal parts

C. To change the color of sheet metal parts

D. To assemble multiple sheet metal parts together

Solution

1. Step 1: Understand the function of cut features

   Cut features are used to remove material from sheet metal parts to create holes or specific shapes.

2. Step 2: Differentiate from other features

   Adding thickness or changing color are not related to cut features; assembling is a separate process.

3. Final Answer:

   To remove material and create holes or shapes in sheet metal parts -> Option A

4. Quick Check:

   Cut features = Remove material [OK]

Hint: Cut features always remove material, never add [OK]

Common Mistakes:

• Confusing cut features with adding thickness
• Thinking cut features change appearance only
• Mixing cut features with assembly operations

2. Which SolidWorks feature is commonly used to create a hole in a sheet metal part?

easy

A. Chamfer

B. Extruded Boss/Base

C. Fillet

D. Hole Wizard

Solution

1. Step 1: Identify hole creation tools

   Hole Wizard is designed specifically to create holes with standard sizes and types in sheet metal parts.

2. Step 2: Exclude other features

   Extruded Boss/Base adds material, Fillet and Chamfer modify edges but do not create holes.

3. Final Answer:

   Hole Wizard -> Option D

4. Quick Check:

   Hole Wizard = Create holes [OK]

Hint: Use Hole Wizard for standard holes, not Extruded Boss [OK]

Common Mistakes:

• Choosing Extruded Boss/Base which adds material
• Confusing edge features like Fillet with hole creation
• Using Chamfer which only bevels edges

3. Given a sheet metal part with a cut feature created using Extruded Cut, what happens to the flat pattern when the cut is added?

medium

A. The flat pattern doubles the cut size

B. The flat pattern updates automatically to include the cut shape

C. The flat pattern deletes the cut feature

D. The flat pattern remains unchanged and ignores the cut

Solution

1. Step 1: Understand flat pattern behavior

   Sheet metal flat patterns automatically update to reflect cut features for accurate manufacturing.

2. Step 2: Eliminate incorrect behaviors

   Flat pattern does not ignore, delete, or distort cut features; it shows the exact cut shape.

3. Final Answer:

   The flat pattern updates automatically to include the cut shape -> Option B

4. Quick Check:

   Flat pattern = Auto update cuts [OK]

Hint: Flat pattern always reflects cut features automatically [OK]

Common Mistakes:

• Assuming flat pattern ignores cuts
• Thinking flat pattern deletes features
• Believing flat pattern changes cut size

4. You created a cut feature on a sheet metal part, but the flat pattern does not show the cut. What is the most likely cause?

medium

A. The flat pattern is not updated or suppressed

B. The cut feature was created on a non-sheet metal body

C. The cut feature was created using Extruded Boss/Base

D. The cut feature was created after flattening the part

Solution

1. Step 1: Check flat pattern status

   If the flat pattern is suppressed or not updated, it won't show recent cut features.

2. Step 2: Review other options

   Cut on non-sheet metal or using Extruded Boss/Base would cause different errors; creating cut after flattening is not standard practice.

3. Final Answer:

   The flat pattern is not updated or suppressed -> Option A

4. Quick Check:

   Flat pattern update = Show cuts [OK]

Hint: Always update flat pattern after adding cuts [OK]

Common Mistakes:

• Ignoring flat pattern suppression
• Confusing cut and boss features
• Assuming cuts after flattening are valid

5. You need to create a complex shape cut on a sheet metal part that updates correctly in the flat pattern. Which approach is best?

hard

A. Use multiple Extruded Cuts and combine them with a single flat pattern update

B. Use Hole Wizard for all complex shapes

C. Create the shape as a sketch and use a single Extruded Cut feature

D. Cut the shape after flattening the sheet metal

Solution

1. Step 1: Choose efficient cut creation

   Creating the complex shape as one sketch and using a single Extruded Cut ensures the flat pattern updates correctly and efficiently.

2. Step 2: Evaluate other options

   Multiple cuts complicate updates; Hole Wizard is for standard holes, not complex shapes; cutting after flattening is not recommended.

3. Final Answer:

   Create the shape as a sketch and use a single Extruded Cut feature -> Option C

4. Quick Check:

   Single sketch cut = Best flat pattern update [OK]

Hint: Use one sketch and one cut for complex shapes [OK]

Common Mistakes:

• Using many cuts causing update issues
• Relying on Hole Wizard for non-hole shapes
• Cutting after flattening sheet metal