Efficient sheet metal design starts long before the press brake — it starts in your CAD model. With a few smart design decisions, you can reduce cutting and bending time, avoid costly rework, and shorten lead times. Below are seven practical optimizations we at Vormelijk Engineering apply as standard to turn ideas into manufacturable products — without surprises at the supplier.

1) Choose material thickness and grade based on function, not feeling

Over-dimensioning costs money — in material, weight, and bending force. Determine stiffness and strength based on actual loads, then choose the closest standard thickness. This prevents unnecessary machining or adjustments later.

2) Design with the available tools

Ask early for your supplier’s laser bed size, minimum inside bend radius, and tooling charts. Keep the inside radius around 1× sheet thickness (or match the existing toolset) and avoid exotic radii that require extra setup time.

3) Minimize bending complexity

Use as few unique bend angles and directions as possible. Group common angles (e.g. 90° and 135°) to reduce tool changes. Consider alternative geometries with fewer bends if functionality stays the same.

4) Add smart reliefs around bends

Prevent cracks by adding bend reliefs or notches along the neutral line. Keep sufficient flange length (at least 3× sheet thickness) and avoid tiny slots that may close up during powder coating.

5) Reduce welding where possible

Corner rivets, clinch nuts, or hook-lip joints can often replace continuous welds. If welding is required, position weld seams away from visible surfaces and plan heat input carefully to avoid distortion.

6) Fasteners: standardization pays off

Use as many identical thread sizes and insert types as possible (for example, M5 clinch nuts). This speeds up assembly, simplifies purchasing, and reduces the chance of picking errors on the shop floor.

7) Align coating and tolerances early

Take coating thickness and post-processing into account. Place critical holes after coating or allow enough clearance. Always specify RAL color and gloss level to prevent guesswork during finishing.

Our approach

  • CAD review focused on bend sequence, tool selection, and weld length
  • Identifying cost drivers (cut length, bend count, unique tools)
  • Fast supplier iterations for realistic lead times

The result: fewer iterations, lower unit cost, and a predictable workflow — from prototype to series production.