December 2024

When designing parts for optimal manufacturability, it’s important to consider certain design features that might impact speed, quality, and cost upfront. Details surrounding relief cuts, cut-out features, and hole placement can make a difference from the quoting stage through production. 

In this blog, we’ll explore some common design considerations and offer a sample of the DFM expertise that comes with partnering with our one-stop sheet metal shop. 

Enable Smooth Bending and Forming with Relief Cuts 

What are relief cuts, and why do they matter?

Relief cuts are small incisions near bend lines to prevent material from puckering or buckling during bending operations. These cuts allow our metal fabrication team to bend material smoothly so that we can avoid misalignments or unsightly holes in your final part. Relief cuts are particularly useful when producing box-like structures or when two bent edges need to meet flush. 

For instance, if you’re designing a part with a square base and sidewalls that will be bent upwards, relief cuts ensure these walls align seamlessly for welding when they meet. When properly executed, this results in a smooth, clean weld along the entire edge.

How to include proper relief cuts in your designs

While many designs come to us with pre-defined relief cuts, they’re not always compatible with our tooling setup. When we notice that relief cuts require adjustment, our team reaches out to customers to inform them of potential issues and confirm changes. In cases where relief cuts are missing altogether from the design, our team will suggest options based on the part’s desired appearance and end-use. 

Prevent Issues Near Bend Lines with Cut-Out Features

Understanding cut-out features 

Cut-out features—shapes or openings within a part—are generally straightforward, but issues can arise when cut-outs are positioned too close to a bend line. For example, a cut-out feature lying within the area pressed by the brake can distort during forming, potentially weakening the part.

How MFP handles cut-out issues

When cut-out features are too close to a bend, the MFP team uses a technique called “stitch-cutting.” Stitch-cutting leaves the profile of the cut-out intact during bending, then manually removes the material afterward to achieve a clean form. This additional step prevents possible bending issues, so the cut-out feature will retain its strength and shape after forming. 

How to properly place cut-out features

When designing your part, try to keep cut-out features away from bend lines wherever possible. If a close placement is unavoidable, our team will work with you to find solutions, advising you on the right approach to manage this feature without compromising the part’s fit, form, and function. Contact our team when you recognize this potential issue so we can work together to address it before it becomes a production roadblock.

Avoid Deformation Near Break Lines with Proper Hole Placement

Why hole placement matters

Hole placement is critical in formed and rolled components. When holes are placed too close to a break line, they may deform during the bending or rolling process. This risk is especially high when dealing with thicker materials, where hole edges may rise or deform if unsupported during forming. 

How MFP addresses challenges with hole placement 

Our tooling capabilities help stabilize parts with holes near bend lines, thus reducing the risk of deformities. Our team is currently working on testing new dies specifically for smaller flanges and closer hole positioning, which offer additional support during forming. However, these tools are still limited to select materials, so maintaining the proper distance between holes and bend lines is ideal. 

To ensure hole positioning doesn’t cause deformities in the part, don’t hesitate to reach out to our team to determine whether or not we need to make adjustments. By knowing your priorities for the part (related to appearance, cost, and precision) and its end use, MFP will offer recommendations that align with your goals.

Leverage DFM Expertise with Metal Fabrication Professionals 

Communication is critical to effective DFM. By collaborating with Metal Fabrication Professionals early in the design phase, our team can address potential manufacturing challenges to ensure the ideal functionality of your parts. Our team’s commitment to proactively supporting our customers effectively minimizes production delays, prevents unnecessary costs, and yields the best products possible for our customers. 

With our extensive DFM experience and variety of precision metal fabrication services, MFP serves as a reliable partner for our customers’ needs. Ready to create high-quality, manufacturable parts? Request a quote to get started!