SMLease Design

Mechanical Product Design & Development Partner

Blog posts : "Sheet Metal Design"

Sheet Metal Gauge Chart

In Sheet Metal manufacturing industry, the thickness of sheet metal sheet is commonly specified by a traditional, non-linear measure known as Gauges. Gauges are defined as per standard rolling mill available. Larger the value of gauge number smaller will be the sheet thickness. 

Sheet Metal Thickness Gauge Chart

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Sheet Metal Electronics Enclosure Design

Sheet Metal electronics enclosure designs that reflect your design intent while satisfying product functional requirements and cost is a challenging task. This article will highlight key design consideration and their impact on product performance: material, assembly techniques, finish etc.


Product Industrial and Assembly Architecture Design


Table Top indoor Electronics EnclosureWall Mounting Enclosure19 Inch 1 U Electronics Chassis  


Industrial / Concept design is very important part of product design. Concept Design defines the product aesthetics. While finalising sheet metal product concept design product manufacturing and assembly also need to take care.

Following factors affects sheet meta…

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Ventilation Options For Sheet Metal Enclosures

Why Ventilation is Required ?

With reduction in size of electronics PCB and mechanical enclosure, Heat dissipation is becoming a challenge. To increase heat dissipation rate in sheet metal enclosures, ventilation holes are required. In sheet metal parts we can create ventilation holes that are aesthetically pleasing while satisfying the requirement of heat dissipation.

Heat transfer calculation for high heat dissipating components need to be done to find optimum area required for convection heat transfer.

Our team can work with you if you are facing any challenges in dissipating heat from your electronics devices you can Contact us for Sheet metal design services.


Decorative ventilation Cutouts

Ventilation holes in sheet metal parts can be used to provide be…

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How To Join Sheet Metal Parts

There are several options like screws, rivets, welding, adhessive, Clinching / tox round joint, folding, are some of commonly used sheet metal parts joining techniques. Selection of best process for joining sheet metal parts depends on the material, its thickness and application.

This guide will give you an overview of the techniques used to join / assembly sheet metal parts

You can contact us for mechanical design services and for any support related to sheet metal assembly process design, sheet metal part design.


Screw Joints

Screws are most commonly used method to make removable joints between two sheet metal parts. Self-Tapping sheet metal screws and machine screws are used to join sheet metal parts.


Self Tapping Sheet Metal Screws

This is most …

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K-Factor Calculator in Sheet Metal Forming

When sheet metal is bent, the inside surface of the bend is compressed and the outer surface is stretched. Somewhere in between the thickness of material lies neutral axis: Line with-in thickness that is neither compressed nor stretched.

The K-Factor in sheet metal Bending is the ratio of the position of neutral axis to the material thickness. Term k-factor is used in cad programmes to calculate sheet-metal blank size. 

Value of k factor will be always less than than 0.5, Value of k factor will be dependent of material, sheet thickness and machine. You can use this calculator for calculating value of k factor in sheet metal for your machine.

If you need any support in design & development of your sheet metal Product, you can contact us for any kind of mechanical design s…

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Sheet Metal Materials

Various types of materials are available for the manufacturing of sheet metals parts. Selection of type of material and grade is done depending on required strength, corrosion resistance, assembly process  and overall cost. 

You can contact us for any kind of mechanical design services and for any support in selection of material for your sheet metal product.


CRCA (Cold Rolled close annealed Steel Sheets)

  • After hot rolling and pickling, the steel is cold rolled to a reduced thickness (which makes it brittle and not too useful), which is then followed by annealing in a closed atmosphere of nitrogen or other non-oxidizing gases (which softens it back up while protecting it from oxidation).
  • CRCA steel is highly prone to rusting. Oil is applied after the annealing,…

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Difference Between Blanking, Punching & Piercing in Sheet Metal

Blanking, Punching and piercing are sheet metal operations in which punch & Die are used to give shape to sheet metal parts. All these are shearing operations that can be done on CNC punching machine and on hydraulic press.

You can Contact Us for Sheet Metal Design & Manufacturing Support.

Blanking is a process in which the punch operation removes a final product from a larger piece of sheet metal.

Punching is a material removal process in which the punch operation removes material from a final piece of sheet metal.

Piercing is process in which punch operation cuts a hole / material by tearing operation from a final piece of sheet metal. Piercing is a blanking operation

You can Contact Us for Sheet Metal Design & Manufacturing Support.


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Sheet Metal Design Guidelines - SMLease Design

To develop better quality parts at reduced cost, some of the common sheet metal design guidelines like: minimum distance between holes, cutouts, slots, distance between holes, cutouts, slots to part edge and bends, multiple bends in same direction, minimum bend radius need to be followed.

You can use this guide to make your sheet metal parts manufacturable. You can Contact Us for Sheet Metal Design & Manufacturing Support.


Minimum inside radius for Sheet Metal Bend:

Minimum bend radii requirements depends on applications and material.When the radius is less than recommended, this can cause material flow problems in soft material and fracturing in hard material which can result in Localized necking or fracture.

It is most economical to use a single bend radiu…

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Hot Rolled Vs Cold Rolled Steel - SMLease Design

Manufacturing Temperature

Process of hot rolling involves rolling steel at a temp above recrystallization temp. During the cooling process steel will shrink and the size and shape of the steel will be less predictable. While cold rolling involves at a temp below recrystallization temp (at around room temp). So there is no chance of steel shrinkage

Manufacturing Cost

Hot rolled steel is cheaper to manufacture as compared with cold rolled steel.


Yield and tensile strength of Cold rolled steel will be higher than hot rolled which makes cold rolled less likely to fracture under pressure

Sheet Quality & Finish

Cold Rolled steel will have closed thickness profile and good surface texture & flatness compared with Hot Rolled Steel. Cold rolled has a smooth and s…

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K- factor / sheet-metal flat pattern calculations - SMLease Design

K-Factor is a very useful term in sheet metal part design and manufacturing. K Factor is used by manufacturer for the calculation of flat pattern of sheet metal parts. Designers use k-factor to determine manufacturability of their designed parts.

You can Contact Us for Sheet Metal Design & Manufacturing Support.


Bending is a manufacturing process by which metal can be deformed plastically to change its shape. Material is stressed beyond its yield strength but below ultimate tensile strength to achieve desired shape. This results in the change of surface area.

After bending there is some increase in the total length e.g. (Length + Height) is not equal to Flat Length.

Flat Length = Length + Height - Bend Deduction



Bend Deduction/Allowance


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Sheet Metal Cutting Operations - SMLease Design

Sheet metal Cutting Operation involves the separation of the metal of the sheet in certain areas. This separation is caused by shearing forces acting on the metal through the edges of the punch and die.

You can Contact Us for Sheet Metal Design & Manufacturing Support.

Sheet Metal Cutting Operations:

Shearing Operation

Cutting process that produces straight line cuts to separate a piece of sheet metal. Shearing is used to cut a sheet parallel or at any angle to an existing edge which is held square. Shearing is primarily used to cut sheet stocks into smaller sizes in preparation for other processes.


Blanking is a cutting process in which a piece of sheet metal is removed from a larger piece of stock by applying a great enough shearing force, the piece re…

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