Designing for Success Strategies for Effective Sheet Metal Prototyping

1. Designing for Success: Strategies for Effective Sheet Metal Prototyping Sheet metal is commonly used in a variety of applications, such as enclosures, cabinets, brackets, and housings, thanks to its lightweight and durability. It is an excellent material for precision-engineered components, offering cost advantages for the manufacturing process. To ensure optimal results, designs should be tailored specifically for sheet metal prototyping. It's essential to use advanced CAD software for accurate and intricate 3D models to prototype with sheet metal. Industries like architecture, automotive, electronics, and aerospace rely on this technology for design optimization, manufacturing feasibility, and cost reduction. The prototyping stage also provides an opportunity for product designers to collaborate with specialists, gaining valuable insights to improve their projects. How to design successful sheet metal prototypes Sheet metal prototyping can be optimized with these strategies:  Prioritize manufacturability - In any prototyping project, always consider the end- use manufacturing process from the get-go. So, work closely with the prototyping specialist to know their capabilities. Some companies can also handle end-use production to streamline the process, reduce complexity, and minimize tooling costs.  Ensure the right material and thickness - The choice of sheet metal gauge and material can impact the product's quality and cost. A specialist can provide details on every material’s mechanical properties and aid in selecting appropriate sheet metals based on the application and rigorous requirements, such as corrosion resistance, ductility, and strength.  Reduce costs with simple bending - Bending radii are among the factors that can affect the cost of sheet metal prototyping. If possible, keep the same radii on all bends to reduce setups. Additionally, this makes the prototyping process cheaper and faster. Just remember the guidelines for the minimum bend radius based on the material’s thickness.  Reduce the need for fasteners and welding - Rivets, screws, and welding can add to the assembly’s complexity and costs. So, consider designs that can be constructed out of one sheet. Or use techniques like bends, slots, and tabs for secure connections and a more streamlined assembly. Need more tips for your sheet metal project?

2. HLH Prototypes can help! Share your project's details and sheet metal prototyping needs with their expert team for a free review. HLH is an ISO 9001:2015 certified rapid manufacturing specialist with a track record of delivering high-quality prototypes cost-effectively and fast.