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AUGUST 2014

Sheet-Metal Design: The New Reality

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Sheet-Metal Design: The New RealitySheet-Metal Design: The New Reality

The primary reason for the knowledge drift: it’s hard to be an expert in all things.

Sheet-metal shops must be more nimble than ever before, particularly those that work as subcontractors. Fabricating parts is no longer enough. Modern sheet-metal shops must be able to analyze and adjust designs from other companies, as well as create their own plans. In theory, it’s easy: designs for the sheet-metal component are drawn up by the client and sent to a sheet-metal subcontractor, who converts those plans into the required part. The reality, however, can be a lot more complicated.

Sheet-metal subcontractors have to be prepared to work with all kinds of data and diagrams and convert it into a digital 3D model readable by the shop’s manufacturing equipment. The client’s plans might consist of hand-drawn sketches, 3D models, pictures of 3D models with chalk notes, or computer files.

The unique manufacturing constraints of sheet metal aren’t always considered at this early stage of design, however. Consequently, some plans won’t be buildable and will need significant changes — or complete overhauls — before manufacturing can begin. If plans have to be sent back to the client for redrafting, time is lost and frustration builds. Increasingly, it’s the specialized sub-contractor who is catching and correcting these errors.

Mistakes often happen because designers tend to think and build in 3D, while manufac-turers start with a flat piece of metal that will later be shaped into the final product. A designer’s finished, 3D model must unfold without any collisions, or unwanted overlaps. Such collisions often aren’t obvious from a 3D model. But with the right tools, a good sheet metal fabricator can spot such problems before manufacturing begins.

Given that the same design can be laid out on a flat piece of sheet metal several ways, a good sheet-metal specialist should also consider the amount of scrap metal generated when deliberating design. The less scrap, the lower the material costs.

The complexity of the build is equally important when analyzing design. The fewer steps involved in manufacturing the component, the faster the part can be made. Complex, expensive fixture systems can sometimes be avoided by simply welding two parts together, for example. Manually moving the metal from one machine to another also takes time. So some aspects of the design are best analyzed by the sheet metal fabricator, as he knows exactly how his shop is set up.

MORE THAN A FABRICATORCAD knowledge is drifting. No longer solely the domain of CAD designers, a growing number of specialized sub-contractors are creating and adjusting designs for their clients to save time and money.

The primary reason for the knowledge drift: it’s hard to be an expert in all things. Yet, a single product is often made of many materials. For example, many toys are primarily made of a plastic. But some, such as high-end toy guns, have internal parts made of sheet metal. The CAD designer for a toy company might be a plastics expert and know a lot about injection molding, but not fully understand sheet metal manufacturing because he mostly works with plastic. This makes it challenging for the toy company to produce complex designs for the sheet-metal parts in-house.

It’s impossible to align goals with clients unless you are clear about your own.

Interference detection

Unfolded part with dimensions

Even parts with numerous holes can be edited easily

Convert solids to sheet metal

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Sheet-Metal Design: The New Reality

Faced with this sort of challenge, many CAD experts are outsourcing sheet-metal design to specialized subcontractors. For guidance, the CAD expert sends the sheet-metal sub-contractor a simplified design plan for the overall shape of a metal component, including only the external dimensions and fixation areas. The plan might arrive as a computer file, or it might be a hand-drawn 2D sketch. While these drawings can be scanned to generate a quick price quote, ultimately they will still need to be converted into a 3D-computer model before the part can be machined. So it’s up to the specialized, sheet metal sub-contractor to figure out how to make the part without collisions or excess scrap, where to add gussets, tabs or weld beads, and create the CAD file.

BECOME A PRODUCTIVITY PARTNERWorking with clients to become an efficient, productive team is key to building loyalty. But it requires clear, ongoing communication. At the start of each project, talk to the client about their primary goal. Is there a particularly tight turnaround time? Offer to design the necessary components so that the product can be manufactured as quickly as possible. Is the client working toward an overall corporate greening program? Offer to reduce packaging material. Reducing the volume of cardboard boxes per shipment can result in lower waste management costs for clients that pay to have their recyclables hauled away. Is the cost of manufacturing the clients’ biggest concern? Discuss a flat plan to minimize scrap sheet metal.

Communication can be particularly tricky when it comes to design changes. Clients can’t always meet in person, but understanding every design change is key to making the best possible product. For long projects, consider a quick Monday morning check-in call. All parties will start the week with the same short-term goals and action items in mind. Monthly meetings with suppliers could be just as valuable. Check-in regularly and find out if there are ways to work with the supplier to reduce costs and improve efficiency. Could invoices be emailed for faster collection? Can deliveries be scheduled for a better time when the loading dock isn’t busy? Try to help clients and suppliers update their process, and find new ways to be more productive. All this can go a long way toward ensuring good bi-directional relationships with everyone involved in making the product.

Creating internal efficiencies is another way to add value for the client. Select software and tools that require minimal training. This can save a sheet metal shop significant resources, in terms of both time and money. Carefully selected, highly intuitive equipment ensures employees experience less frustration, too. Avoid software bloated with features you’ll likely never use. That bloat can cost considerable cash. Look for affordable solutions with just the features and functions truly required.

THE FUTURE OF SHEET METALCAD knowledge now permeates the product development process, from designer to fabricator. As knowledge continues to drift and sheet-metal workers become increasingly involved with design, it’s important to nurture relationships with clients. Loyal clients will help to form a solid foundation for your business.

Gleaning knowledge about a client’s evolving goals will also help everyone prepare for the future. Openness and clarity is key. It’s impossible to align goals with clients unless you are clear about your own, too. Create a mission statement, as well as one-year and five-year goals for the shop. Spread the word to employees, clients, and suppliers. Remember to communicate your message from a positive and not a desperate place. Goals should inspire, not induce anxiety!

Be the rapid, reliable problem solver.

Double walls

Create hinge

Specialized sheet metal tools

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Sheet-Metal Design: The New Reality

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Once goals are set, it’s time to think about the tools required. Investing in the right software package is key. For example, direct 3D modeling is a perfect fit for sheet metal fabrication. It provides the flexibility and functionality needed to edit and repair models quickly. Ultimately, direct modeling allows sheet metal shops to optimize their entire workflow and keep shop floor downtime to a minimum. SpaceClaim’s direct modeling software is highly intuitive and offers a relevant feature set; it doesn’t require formal education in CAD design. Training is free and it takes less than a week to get started. The software also has a low total cost of ownership, making it a great choice for efficient shops.

SpaceClaim’s flexible design tools also make it easy for anyone involved in sheet-metal product development to spot and resolve design problems. Collisions, for example, are automatically highlighted on screen. Features, such as gussets and tabs, are easily and added; there’s no need to search feature trees for just the right element.

SpaceClaim’s flexible software also allows for different design styles. Fabricators can type in exact measurements, or use the pull, move, fill, and combine tools to create complex 3D shapes. Need to change the size of a tab? You can directly modify the geometry by pulling on its edge. Other software packages make it difficult to test alternative designs without starting over or breaking the existing model. SpaceClaim’s software is designed to elimi-nate those kinds of limitation and make it easy to trial changes. Even a traditional sheet metal fabricator will feel comfortable working with SpaceClaim tools.

They will also enjoy better client communication with SpaceClaim’s LiveReview software. Using LiveReview, it’s quick and easy to collaboratively create sheet-metal components online — with an unlimited number of colleagues. All meeting participants can talk about their ideas, rotate and markup models, take screenshots and measurements. The host can also quickly adapt the design, in real time, to show how something the client just suggested will affect the overall look of the product. Best of all, clients don’t have to own SpaceClaim software to attend LiveReview meetings. There’s no software to download or install. All that’s needed is an up-to-date Web browser* and an Internet connection.

Be the rapid, reliable problem solver — the sheet metal shop that can create designs from scratch, or perfect the client’s plan. Let clients know they can submit plans in any format they prefer. Not set up to support that claim? Consider investing in software, such as SpaceClaim’s, that easily imports all CAD file types. SpaceClaim’s philosophy, which is reflected in its software, is to foster an open-environment that promotes innovation, productivity and better business packages.

The sheet metal industry has a solid future ahead. Lightweight yet strong, conductive and non-corrosive: the properties of sheet metal make it ideal for a myriad of applications. But sheet metal manufacturing is a competitive business and particularly challenging for small shops. Clients want a sheet-metal shop that can scrutinize designs, correct flaws, provide a cost estimate, and make the product — all on a tight deadline.

Partner with your clients to work toward peak productivity and foster loyalty. Share your knowledge, goals, and resources. These small changes can help make your business stand out, and ensure success.

*LiveReview will run on any browser that is WebGL enabled.