Sheet metal bracket design

Explore the design considerations in sheet metal bracket design along with example for design engineers

Design considerations and question to ask in sheet metal bracket design

  1. Material selection :

What material to choose for the sheet metal part?

Steel? Aluminum alloy? Or any other metal?

If chosen then which grade?

Whether the steel selected is formable / bendable easily.

Whether the grade and thickness is available?

  1. Overall feasibility of process:

Evaluating the manufacturing feasibility of sheet metal brackets is crucial to ensure that the design can be produced efficiently, cost-effectively. Whether the geometry required can be manufactured through sheet metal processes available.

Are there internal cavities which cannot be formed?

Are there deep channels which cannot be bent

Whether tooling and fixturing is feasible?

What thickness of material is feasible to bend. From within constraints?

  1. Bend radii

Whether the Bend radius provided is sufficient from forming/bending point of view as well as from the point of view of function?

  1. Hole , tab and other features

Are there any holes near the Bend , if so are they spaced away to avoid distortion .

If there is a tab , is it wide enough to allow for cutting operation

Whether the holes, notches or any other features contribute to stress concentration?

  1. Stiffening features – Flanges and stiffeners

How can we improve the stiffness of sheet metal bracket?

Where can flanges be added or stiffeners like ribs or embosses be added to improve stiffness?

What will be the manufacturing process implication of adding these features?

How much cost will it increase vs how much benefit they provide in terms of function / load bearing?

  1. Tolerances

What range of tolerances are required on location of holes? Or width of parts or flatness of surfaces?

Whether these tolerances are actually achievable in process required to make them ? are they justified?

How to create robust design which is functional even with open tolerances?

  1. Optimization for strength and light weight design

Where can material be added and where can it be removed?

What design features can be added to reduce the stress level ?

CAD demonstration videos on design of sheet metal brackets:


For more content on sheet metal design have a look at the list of articles here :

Sheet metal design guidelines

How to Stiffen Sheet metal design

Sheet metal Formability

Bend allowance

Bend Deduction

Sheet metal stamping

Learning Sheet metal design

Categories: : Sheet metal