Sheet Metal Design Guidelines F eatur es L ist F o x c o nn . do c _ r ev .

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HON HAI PRECISION ENCLOSURE GROUP

 SUB J ECT :     D OCUM ENT NO. : 9 8 -0 5 3 0 0 7
Sh e e t M e t a l D e s i g n Gu i d e l i n e s
PAGE 1 O F 6 8 R EV 0 1

Note:

T h i s d oc u m en t i s u n d er d ev el op m en t b etw een HO N HA I
a n d C i s c o M ec h a n i c a l G u i d el i n es a n d C en tr a l D F M tea m
m em b er s . T h e d oc u m en t w i l l b e p u b l i s h ed i n th e C i s c o
M ec h a n i c a l P r od u c a b i l i ty G u i d el i n es w eb s i te, m a n a g ed b y
C h r i s ti n e Nol a n B r a d y . T h i s d oc u m en t i s ow n ed b y HO N
HA I , n ot of f i c i a l l y a p p r ov ed b y C i s c o, a n d s h ou l d b e u s ed
f or r ef er en c e on l y , b y i n ter n a l C i s c o E n g i n eer i n g a n d
M a n u f a c tu r i n g .

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21 20 19 02 18 17 16 15 07 12
21

22
01 05

23 14
24
13
25
01
26
27
12
28
07

11

01 02 03 04 05 06 07 08 01 09 10

THE MOST COMMONLY SHEET METAL FEATURES:

No.| FEATU RE NAME No.| FEATU RE NAME No.| FEATU RE NAME

Cu t ou t f eatu r es

01 HO LE 05 RELIEF 09 NO TCH
11 P ERFO RATED 13 CO U NTERS INK 21 CO RNER

Bendi ng f eatu r es

02 BEND 04 CU RL 06 O FFS ET BENDS

10 HEM 20 TAB 28 U -BEND

For m ed f eatu r es

03 EXTRU DE FO RM 07 EMBO S S 08 CO INING EDGE

12 LANCE FO RM 14 HO O K FEATU RE 15 RIB
16 HALF-S HEARING 17 RAIS ED LETTER ICO N 18 DIMP LE
19 S TAMP ING ICO NS 22 CARD GU IDE FO RM 23 RO U ND HEM
24 EXTRU DED HO LE 25 THREAD FO RM 26 GU S S ET
27 S P O O N

Notes (f or thi s Desi g n Gu i del i ne sp ec i f i c ati on):

1. The m ater i al i s l ow c ar bon steel ;
2. The standar d m ater i al thi c k ness r ang i ng f r om .030” to .059”;

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 Sheet Metal Design Guidelines H o le F o x c o nn . do c _ r ev . 0 1

TI TLE: HOLE & SLOT ( P UNCH) ( #0 1 )

DESCRI P TI ON: A c u t i n the m i ddl e of the sheet m etal su r f ac e i s c al l ed a Hol e.

DESI GN GUI DELI NE: The m i ni m u m di am eter of a hol e (or wi dth of a sl ot) shou l d be eq u al to 1.2 ti m es
m ater i al thi c k ness p l u s .008”, or .048”, whi c hev er i s g r eater .

HOLE

D (m i ni m u m ) = 1.2x T + .008“, or .048“, whi c hev er i s g r eater

Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D m odel shou l d i nc l u de the hol e di am eter , l eng th and wi dth of the
sl ot.

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 Sheet Metal Design Guidelines H o le F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Ho l e t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (G) between hol es i s di r ec tl y p r op or ti onal
to the si z e and shap e of the hol es and the m ater i al thi c k ness.
Bu t the m i ni m u m di stanc e between c i r c u l ar hol es i s 1.2 ti m es m ater i al thi c k ness.

Ho l e t o Edg e
Des i g n Gu i del i n e: The m i ni m u m di stanc e (G) between a hol e and the edg e of the m ater i al m u st be
m ai ntai ned. The m i ni m u m r ec om m ended di stanc e between the hol e and the edg e i s di r ec tl y
p r op or ti onal to the si z e and shap e of the hol e and the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D: Di am eter or m i ni m u m di m ensi on of sl ot
L: Leng th of sl ot
T: Mater i al Thi c k ness
G: m i ni m u m Di stanc e di m ensi on

When L i s T to 10T then m i ni m u m G = 2T

When L i s 10T to 25T then m i ni m u m G = 4T
When L i s ov er 25T then m i ni m u m G = 6T

Rec o m m en ded

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Ho l e t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) between the edg e of a hol e to a bend
i s two ti m es the m ater i al thi c k ness p l u s the r adi u s of the bend.
Sl o t t o Ben d
Des i g n Gu i del i n e: The m i ni m u m di stanc e (D3) f r om the i nsi de su r f ac e of a bend to the edg e of a
sl ot i s di r ec tl y p r op or ti onal to the l eng th of the sl ot, m ater i al thi c k ness and the r adi u s of the bend.
Ho l e t o Fo r m
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) f r om the edg e of a hol e to the base of
the f or m i s thr ee ti m es the m ater i al thi c k ness p l u s the f or m r adi u s.
Ho l e t h r o u g h a Ben d
Des i g n Gu i del i n e: When a hol e g oes thr ou g h a bend, the l eadi ng edg es of the hol e shou l d ex tend a
m i ni m u m di stanc e (D5) bey ond (or both si des of ) the bend. Thi s m i ni m u m di stanc e shou l d be two
ti m es the m ater i al thi c k ness or the thi c k ness of m ater i al p l u s the r adi u s of a bend, whi c hev er i s
g r eater .
Fea t u r e P o s i t i o n

D2 (m i ni m u m ) = 2T + R1

When R1 = <.118” and

L < 1.0” then D3 (m i n) = 2.5T + R1
L i s 1.0” to 2.0” then D3 (m i n) = 3T + R1
L > 2.0” then D3 (m i n) = 3.5T + R1

When R1 > .118” and

L i s l ess than 20T then D3 (m i n) = 3.5T + R1
L i s ov er 20T then D3 (m i n) = 6T + R1

D4 (m i ni m u m ) = 3T + R2
D5 (m i ni m u m ) = 2T or T + R1, whi c hev er i s g r eater
Rec o m m en ded

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 Sheet Metal Design Guidelines R elief F o x c o nn . do c _ r ev . 0 1

TI TLE: RELI EF ( #0 5 )

DESCRI P TI ON: When a bend does not ex tend the enti r e l eng th of a p ar t, or a f or m i s c l ose
to other sheet m etal f eatu r es, the r el i ef c an hel p c ontr ol the sheet m etal m ater i al behav i or and
p r ev ents u nwanted def or m ati on.
The r ec om m ended r el i ef ty p e i s r ec tang u l ar .
The obr ou nd ty p e r el i ef i s p r ef er r ed. (H/ T)

DESI GN GUI DELI NE: The m i ni m u m dep th of a bend r el i ef (D) i s eq u al to the m ater i al
thi c k ness p l u s the r adi u s of a bend. The m i ni m u m wi dth (W) of a bend r el i ef i s eq u al to 1.5
ti m es m ater i al thi c k ness or 0.059” (1.50m m ), whi c hev er i s g r eater .

RELI EF

W (m i ni m u m ) = 1.5X T or .059”, whi c hev er

i s g r eater ; Tear ty p e r el i ef .
D (m i ni m u m ) = T + R
Rec o m m en ded No t Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y show f ol l owi ng i nf or m ati on:
r el i ef wi dth (W), r el i ef l eng th (D).

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FEATURE P OSI TI ON

Rel i ef t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e between a r el i ef and a bend
f ol l ows the r u l es of a hol e to a bend. The m i ni m u m r ec om m ended di stanc e (D) i s thr ee
ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

Mak e the r el i ev es to g o thr ou g h the bend

D(m i ni m u m ) < 3T
i f D(m i ni m u m ) i s l ess than 3T
Rec o m m en ded No t Rec o m m en ded

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 Sheet Metal Design Guidelines N o tc h F o x c o nn . do c _ r ev . 0 1

TI TLE: NOTCH ( #0 9 )

DESCRI P TI ON: An i ntr u si on or c u t i nto the edg e of the sheet m etal i s c al l ed a Notc h.

DESI GN GUI DELI NE: The m i ni m u m p r ef er r ed wi dth of a notc h i s .060” or 1.5 ti m es the
m ater i al thi c k ness whi c hev er i s g r eater . Ty p i c al notc h l eng th c an be u p to f i v e ti m es the wi dth,
when p u nc hed at the m i ni m u m wi dth di m ensi on.

NOTCH

W (m i ni m u m ) = 1.5x T or .060” whi c hev er i s W(m i ni m u m ) < 1.5x T

g r eater
Rec o m m en ded No t Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y show f ol l owi ng i nf or m ati on:
notc h wi dth (W).

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FEATURE P OSI TI ON

No t c h t o No t c h
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) between notc hes i s two
ti m es the m ater i al thi c k ness.

No t c h t o Ho l e o r Cu t o u t
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) m u st be m ai ntai ned
between a hol e and edg e of a notc h. The m i ni m u m r ec om m ended di stanc e i s 1.2 ti m es
the m ater i al thi c k ness.

No t c h t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) f r om the i nsi de su r f ac e of
the bend to the edg e of a notc h shou l d f ol l ow r ec om m endati on f or sl ot to bend on p ag e 4.

No t c h t h r o u g h a Ben d
Des i g n Gu i del i n e: When a notc h g oes thr ou g h a bend, the bottom or si de edg es of the
notc h shou l d ex tend a m i ni m u m di stanc e (D4) bey ond the bend, eq u al to the thi c k ness
of m ater i al p l u s the bend r adi u s.

Fea t u r e P o s i t i o n

L: sl ot l eng th

D1 (m i ni m u m ) = 2T
D2 (m i ni m u m ) = 1.5T

When L i s l ess than 1.0” then D3 (m i ni m u m ) = 2.5T + R

When L i s 1.0” to 2.0” then D3 (m i ni m u m ) = 3T + R
When L i s ov er 2.0” then D3 (m i ni m u m ) = 3.5T + R

D4 (m i ni m u m ) = T + R or 2T, whi c hev er i s g r eater

Rec o m m en ded

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 Sheet Metal Design Guidelines P er f o r ated m etal F o x c o nn . do c _ r ev . 0 1

TI TLE: P ERFORATED METAL ( #1 1 )

DESCRI P TI ON: A p atter n wi th hol es on sheet m etal su r f ac e i s c al l ed p er f or ated m etal .

DESI GN GUI DELI NE: The r ec om m ended m i ni m u m di stanc e between the hol es i s eq u al to
1.2 ti m es the m ater i al thi c k ness.

P ERFORATED HOLE

D (m i ni m u m ) = 1.2 T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D m odel shou l d c ar e f or the di stanc e (D) between the
hol es.

If f or ai r f l ow r eason the abov e r ec om m ended di m ensi on c annot be m et, one c an c onsi der the
f ol l owi ng :

1. For c osm eti c p er f or ated p ar t, sandwi c h an of f -the-shel f p er f or ated m ater i al between two
sheet m etal p ar ts.
2. For non-c osm eti c p er f or ated p ar t, ac c ep t def or m ati on and/ or m ater i al br eak ag e.

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FEATURE P OSI TI ON

P er f o r a t ed h o l e t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D) i s:
Fr om the edg e of a c i r c u l ar hol e to a bend (D1) i s thr ee ti m es the m ater i al thi c k ness.
Fr om the r ec tang u l ar hol e to a bend (D2) i s eq u al to 3.5 ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 3T
D2 (m i ni m u m ) = 3.5T
Rec o m m en ded

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 Sheet Metal Design Guidelines C o unter sink F o x c o nn . do c _ r ev . 0 1

TI TLE: COUNTERSI NK ( #1 3)

DESCRI P TI ON: A Cou nter si nk i s a c oni c al dep r essi on at an ex i sti ng hol e i n the sheet m etal
su r f ac e. A c ou nter si nk u su al l y u sed i n c onj u nc ti on wi th har dwar e.

DESI GN GUI DELI NE: The m i ni m u m dep th of the nec k seg m ent (S ) of a c ou nter si nk i s eq u al
to .008”.

COUNTERSI NK

S (r ec om m ended) = .008“
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on:
m i ni m u m nec k hei g ht (S ), m aj or di am eter of the c ou nter si nk (D), thr ou g h hol e di am eter (d)
and ang l e of the c ou nter si nk (A). Al l these i nf o shou l d m atc h wi th c or r esp ondi ng har dwar e
u sed.

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 Sheet Metal Design Guidelines C o unter sink F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Co u n t er s i n k t o Fo r m
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) between the m aj or
di am eter of a c ou nter si nk and a f or m i s f ou r ti m es the m ater i al thi c k ness p l u s the f or m
r adi u s.

Co u n t er s i n k t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) between the m aj or
di am eter of a c ou nter si nk and a bend i s f ou r ti m es the m ater i al thi c k ness p l u s the bend
r adi u s.

Co u n t er s i n k t o Co u n t er s i n k
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) between the m aj or
di am eter s of two c ou nter si nk s i s eq u al to si x ti m es the m ater i al thi c k ness.

Co u n t er s i n k t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between the m aj or
di am eter of a c ou nter si nk and an edg e i s f ou r ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1 (m i ni m u m )= 4T + R2
D2 (m i ni m u m )= 4T + R1
D3 (m i ni m u m ) = 6T
D4 (m i ni m u m ) = 4T
Rec o m m en ded

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TI TLE: CORNER ( #2 1 )

DESCRI P TI ON: The c or ner s i nc l u de the shar p , r adi u s (f i l l et) and c ham f er ed.

DESI GN GUI DELI NE: For a r adi u s (f i l l et) c or ner , the m i ni m u m r adi u s of the c or ner shou l d
nev er be l ess than .012” (H/ T) or .059” (S / T).

CORNER – Ra di u s

R (r ec om m ended) = .059”(1.50m m ) R(m i ni m u m ) < .059”(1.50m m )

Rec o m m en ded No t Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: c or ner
of the g eom etr y and the ou ter and i nner c or ner shou l d add r adi u s.

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 Sheet Metal Design Guidelines C o r ner F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Co r n er t o Ben d
Des i g n Gu i del i n e: 1. For Radi u s Cor ner , the m i ni m u m r ec om m ended di stanc e between
r ou nd to the bend i s 2.5 ti m es the m ater i al thi c k ness p l u s .059”.

CORNER - Ra di u s

D (m i ni m u m ) = 2.5XT + .059”, D (m i ni m u m ) < 2.5XT + .059”

R = .059”
Rec o m m en ded No t Rec o m m en ded

2. For Cham f er Cor ner , the m i ni m u m r ec om m ended di stanc e between c ham f er to the
bend i s 2.5 ti m es the m ater i al thi c k ness p l u s .059”.

CORNER - Ch a m f er

D (m i ni m u m ) = 2.5XT + .059”, D (m i ni m u m ) < 2.5XT + .059”

D = .059
Rec o m m en ded No t Rec o m m en ded

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Co r n er a n d p a i n t ( f i n i s h )
Des i g n Gu i del i n e: The S har p Cor ner wi l l l ead to p ai nti ng p r obl em s i f the c or ner
su r f ac es wi l l be p ai nted.

CORNER

P ai nt the su r f ac es wi th Rou nd P ai nt the su r f ac es wi th S har p

Cor ner Cor ner
Rec o m m en ded No t Rec o m m en ded

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 Sheet Metal Design Guidelines B ending F o x c o nn . do c _ r ev . 0 1

TI TLE: BENDI NG ( #0 2 )

DESCRI P TI ON: A bend i s a f or m that m ak es the sheet m etal wal l i nto an ang u l ar shap e.

DESI GN GUI DELI NE: The bend has two c har ac ter i sti c s: the bendi ng ang l e and the bendi ng
r adi u s. The m ax i m u m r ec om m ended r adi u s f or a bend i s .020”. A bendi ng ang l e i s
r ec om m ended to be a r i g ht or obtu se ang l e.

BENDI NG

A (m i ni m u m ) = 90 DEG Bend ang l e i s an ac u te ang l e

Rec o m m en ded No t Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on:
m i ni m u m bendi ng r adi u s(R) and bendi ng ang l e (A).

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FEATURE P OSI TI ON

Ben d t o edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended hei g ht (H) of a bend f l ang e m easu r ed
f r om the i nsi de su r f ac e of the bend i s eq u al to 2.5 ti m es the m ater i al thi c k ness p l u s the
r adi u s of the bend.

Fea t u r e P o s i t i o n

H (m i ni m u m ) = 2.5T + R
Rec o m m en ded

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 Sheet Metal Design Guidelines C ur l F o x c o nn . do c _ r ev . 0 1

TI TLE: CURL ( #0 4)

DESCRI P TI ON: A Cu r l i s a f or m that m ak es the sheet m etal f l ang e i nto a r ol l ed shap e. It

u su al l y u sed as a m eans of j oi ni ng two c om p onents and i n the f or m of a hi ng e.

DESI GN GUI DELI NE: The m i ni m u m i nsi de r adi u s of a c u r l i s eq u al to two ti m es the m ater i al
thi c k ness; the m i ni m u m op eni ng g ap i s eq u al to one m ater i al thi c k ness.

CURL

G (m i ni m u m ) = T
R (m i ni m u m ) = 2T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on:
m i ni m u m op en g ap (G), i nsi de r adi u s (R).

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 Sheet Metal Design Guidelines C ur l F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Cu r l t o Ho le
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om a hol e i s:
Fr om ac u r l to the edg e of a hol e (D1a): one ti m es the m ater i al thi c k ness p l u s r adi u s of
the c u r l.
Fr om ac u r l to the edg e of a sl ot (D1b): two ti m es the m ater i al thi c k ness p l u s r adi u s of
the c u r l.

Cu r l t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) that a c u r l shou l d be f r om
a bend i s:
As an i nter nal bend (D2a): ni ne ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of the
c u r l.
As an ex ter nal bend (D2b): si x ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of the
c u r l.

Fea t u r e P o s i t i o n

D1a (m i ni m u m ) = T + R

When L i s l ess than .39“ then D1b (m i ni m u m ) = 2T + R

When L i s .39” to 1.96” then D1b(m i ni m u m ) = 6T+ R
When L i s ov er 1.96” then D1b(m i ni m u m ) = 10T

D2a (m i ni m u m ) = 9T + R
D2b (m i ni m u m ) = 6T + R
Rec o m m en ded

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 Sheet Metal Design Guidelines O f f set b ends F o x c o nn . do c _ r ev . 0 1

TI TLE: OFFSET BENDS ( #0 6)

DESCRI P TI ON: An of f set bend, or a j og g l e, i s two v er y shor t bends (2K <H wher e K i s the K -
f ac tor ) f or m ed si m u l taneou sl y . It i s u sed to j og g l e other sheet m etal su r f ac e or ser v e as a
g u i de.

DESI GN GUI DELI NE: The r ec om m ended bends ang l es ar e obtu se ang l es or r i g ht ang l es.
The m ax i m u m hei g ht (H) of an of f set bend i s f i v e ti m es of the m ater i al thi c k ness.

OFFSET BENDS

H (m ax i m u m ) = 5T
A1 (m i ni m u m ) = 90

A2 (r ec om m ended)  90 °
If H i s ov er 2T then R (r ec om m ended) = .039”
Rec o m m en ded
GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: of f set
bends hei g ht (H), f i x ed si de ang l e (A1), f i x ed bend r adi u s (R0), bend c r eati ng si de r adi u s (R),
ang el (A2).

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FEATURE P OSI TI ON

Of f s et b en ds t o Rec t a n g u l a r Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om the bend i nsi de
su r f ac e to the edg e of a hol e i s eq u al to ei g ht ti m es the m ater i al thi c k ness p l u s the
r adi u s of bend.

Of f s et b en ds t o Ex t r u ded h o l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om the bend i nsi de
su r f ac e to the m aj or di am eter of ex tr u si on i s eq u al to 2.5 ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

When L i s l ess than .80” then D1 (m i ni m u m ) = 8T + R

When L i s ov er .80” then D1 (m i ni m u m ) = 12T + R
(i f the p u nc h di r ec ti on i s downwar d, then D1(m i ni m u m ) c an be 3T)
D2 (m i ni m u m ) = 2.5T
Rec o m m en ded

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 Sheet Metal Design Guidelines H em F o x c o nn . do c _ r ev . 0 1

TI TLE: HEM ( #1 0 )

DESCRI P TI ON: A Hem has a f u l l r ou nd f eatu r e and a r etu r n f l ang e. It i s u sed as a m ethod of
el i m i nati ng shar p edg e or to p r ov i de addi ti onal sti f f ness to the edg e of a su r f ac e. Ther e ar e
thr ee ty p es of hem : c l osed hem , op en hem and tear dr op hem .
The c l osed hem i s the str ong l y r ec om m ended op ti on i f the hem i s onl y u sed as a m ethod of
el i m i nati ng shar p edg e. The tear dr op hem i s not r ec om m ended.

DESI GN GUI DELI NE:

1. For the c l osed hem (no i nsi de r adi u s), r etu r n f l ang e l eng th (H) f r om ou tsi de the bend
shou l d be eq u al to or g r eater than f ou r ti m es the m ater i al thi c k ness.
Thi s ty p e of hem (c l osed hem ) i s not recommended i n the f ol l owi ng si tu ati on:

The hem g eom etr y wi l l be p ai nted;

The m ater i al i s S S T & al u m i nu m ;

The p ar t i s p ost p l ated;

Cl o s ed Hem

H (m i ni m u m ) = 4T
Rec o m m en ded

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GUI DELI NES FOR 3D GEOMETRY: 3D g eom etr y of c l osed hem shou l d c l ear l y i ndi c ate
f ol l owi ng i nf or m ati on: the r etu r n f l ang e l eng th (H) and the z er o r adi u s of the i nsi de r adi u s.

2. For op en Hem ( the bend ang l e i s 180 °), the m i ni m u m i nsi de di am eter shou l d be eq u al to
the m ater i al thi c k ness, r etu r n f l ang e l eng th (H) f r om ou tsi de the bend i s eq u al to or
g r eater than si x ti m es the m ater i al thi c k ness.
The g ap (G) c an be set by i nc r em ents of the m ater i al thi c k ness.

Op en Hem

D (m i ni m u m ) = G
H (m i ni m u m ) = 6T
G (r ec om m ended)  T or G (r ec om m ended)  3T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D g eom etr y of op en hem shou l d c l ear l y i ndi c ate
f ol l owi ng i nf or m ati on: the r etu r n f l ang e l eng th (H), the i nsi de di am eter (D) and the op eni ng
g ap (G).

Ti p s f o r t h e Op en Hem

The r ec om m ended op ti on f or O p en Hem shown i n bel ow i m ag e i s onl y u sed f or H/ T.

The di m p l es on the r etu r n f l ang e ar e u sed to ensu r e the g ap of the op en hem .
The g ap of an op en hem shou l d be m or e than .020” i f the m ater i al i s CRS .

Op en Hem

The di m p l es shou l d be ar r ay ed on di f f er ent l i nes.

Rec o m m en ded

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3. For the tear dr op Hem (the bend ang el i s g r eater than 180 °), the m i ni m u m di am eter
shou l d be eq u al to the m ater i al thi c k ness, r etu r n f l ang e hei g ht f r om ou tsi de the bend i s
eq u al to or g r eater than si x ti m es the m ater i al thi c k ness. The r ec om m ended m i ni m u m
hem op eni ng g ap shou l d be eq u al to ¼ of the m ater i al thi c k ness.

If the m ater i al i s GI, the Tear dr op hem g eom etr y i s not r ec om m ended.

Tea r dr o p Hem

D (m i ni m u m ) = T, H (m i ni m u m ) = 6T, G (m i ni m u m ) = 1/ 4T
No t Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D g eom etr y of Tear dr op hem shou l d c l ear l y i ndi c ate
f ol l owi ng i nf or m ati on: the r etu r n f l ang e l eng th (H), the i nsi de di am eter (D) and the g ap (G).

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FEATURE P OSI TI ON

Hem t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) i s:
The m i ni m u m di stanc e (D1a) f r om the edg e of the hol e shou l d be f r om the ou tsi de edg e
of a hem i s two ti m es the m ater i al thi c k ness p l u s the r adi u s of the hem .
The m i ni m u m di stanc e (D1b) f r om the edg e of the sl ot hol e shou l d be f r om the l eadi ng
edg e of the r etu r n f l ang e i s f i v e ti m es the m ater i al thi c k ness.

Hem t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om a bend i s:
As an i nter nal bend (D2a): si x ti m es the m ater i al thi c k ness.
As an ex ter nal bend (D2b): f ou r ti m es the m ater i al thi c k ness.

Hem t o f o r m
Des i g n Gu i del i n e: the m i ni m u m r ec om m ended di stanc e (D3) f r om the ou tsi de edg e
shou l d be f r om the ou tsi de edg e of a hem i s f i v e ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1a (m i ni m u m ) = 2T + R
D1b (m i ni m u m) = 5T
D2a (m i ni m u m
) = 6T
D2b (m i ni m u m
) = 4T
D3 (m i ni m u m ) = 5T
Rec o m m en ded

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Hem t o Hem
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between two hem s wou l d
hav e to be ev al u ated base u p on sp ec i f i c desi g n r eq u i r em ent. Ther e ar e two ty p es her e:
Both the hem s on the sam e si de: the di stanc e (D4a) i s eq u al to the m ater i al thi c k ness.
Both the hem s on the di f f er ent si des: the di stanc e (D4b) i s eq u al to f i v e ti m es the
m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D4a (m i ni m u m ) = T
D4b (m i ni m u m ) = 5T
Rec o m m en ded

Op en Hem w i t h a Ben d
Des i g n Gu i del i n e: Thi s ty p e hem i nc l u des a i nwar d f l ang e attac hed the edg e of a hem , The
m i ni m u m i nsi de di am eter shou l d be eq u al to the m ater i al thi c k ness, r etu r n f l ang e m i ni m u m
hei g ht f r om ou tsi de the bend i s eq u al to or g r eater than ei g ht ti m es the m ater i al thi c k ness.

The di m p l es or other g eom etr y i s a g ood op ti on to c ontr ol the g ap of an op en hem .

A c o m p l ex Hem

R (m i ni m u m ) = T/ 2, H (m i ni m u m ) = 8T, G (m i ni m u m ) = .010“
Rec o m m en ded

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Cl o s ed Hem w i t h a Ben d
Des i g n Gu i del i n e: Thi s ty p e g eom etr y i nc l u des a ou twar d f l ang e, The hem i s a c l osed ty p e
hem , r etu r n f l ang e m i ni m u m l eng th (L) f r om ou tsi de the bend i s eq u al to or g r eater than ei g ht
ti m es the m ater i al thi c k ness p l u s the r adi u s of the bend; the f l ang e m i ni m u m hei g ht i s eq u al to
2.5 ti m es the m ater i al thi c k ness.

A c o m p l ex Hem

H (m i ni m u m ) = 2.5T, L (m i ni m u m ) = 8T + R
Rec o m m en ded

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TI TLE: TAB ( #2 0 )

DESCRI P TI ON: A p r otr u si on f r om an edg e i s c al l ed a tab.

DESI GN GUI DELI NE: The m i ni m u m wi dth of a tab i s eq u al to two ti m es the m ater i al
thi c k ness or .125”, whi c hev er i s g r eater . The m ax i m u m r ec om m ended l eng th (H) of a tab i s
f i v e ti m es the wi dth of the tab.

TAB

W (m i ni m u m ) = 2T or .125“, whi c hev er i s g r eater

H (m ax i m u m ) = 5W
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: the tab
wi dth (W), tab l eng th (H).

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FEATURE P OSI TI ON

Ta b t o Ta b
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D) between tabs i s eq u al to
1.5 ti m es the m ater i al thi c k ness or .060”, whi c hev er i s g r eater .

Fea t u r e P o s i t i o n

D (m i ni m u m ) = 1.5T or .060“, whi c hev er i s g r eater

Rec o m m en ded

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TI TLE: EX TRUDED FORM ( #0 3)

DESCRI P TI ON: An Ex tr u ded f or m i s a dr awi ng f or m f r om the ex i sti ng hol e on the sheet

m etal su r f ac e. The di stor ti on wi l l oc c u r at the f or m c or ner s when f or m ed.

DESI GN GUI DELI NE: The m ax i m u m r ec om m ended hei g ht of the ex tr u ded f l ang e i s eq u al to
f ou r ti m es the m ater i al thi c k ness. The m i ni m u m r ec om m ended wi dth of the f or m i s eq u al to
two ti m es the f or m hei g ht p l u s thr ee ti m es the m ater i al thi c k ness. The obr ou nd g eom etr y
shap e i s the r ec om m ended op ti on f or thi s f or m .

EX TRUDED FORM

H (m ax i m u m ) = 4T
W (m i ni m u m )= 2H + 3T
A (m ax i m u m )= 90 DEG
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: f or m
wi dth (W), f or m hei g ht (H), base r adi u s (R), and tap er ang el (A).

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FEATURE P OSI TI ON

Ex t r u ded f o r m t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) i s:
Fr om the edg e of a hol e to the ex tr u ded f or m (D1a) i s f ou r ti m es the m ater i al thi c k ness;
Fr om the edg e of a sl ot to the f or m (D1b) i s di r ec tl y r el ated to the l eng th of the sl ot and
the m ater i al thi c k ness.

Ex t r u ded f o r m t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om the ex tr u ded f or m to
the bend i s ei g ht ti m es the m ater i al thi c k ness p l u s the r adi u s of the bend.

Ex t r u ded f o r m t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) f r om the ex tr u ded f or m to
the edg e i s f i v e ti m es the m ater i al thi c k ness.

Ex t r u ded f o r m t o Ex t r u ded f o r m
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between the f or m s i s
ei g ht ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1a (m i ni m u m ) = 4T

When L i s l ess .40“ then D1b (m i ni m u m ) = 4T

When L i s .40 to 1.90” then D1b (m i ni m u m ) = 8T
When L i s ov er 1.90 then D1b (m i ni m u m ) = 12T

D2 (m i ni m u m )= 8T + R
D3 (m i ni m u m ) = 5T
D4 (m i ni m u m ) = 8T
Rec o m m en ded

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Th e Ca r d g u i de u s i n g ex t r u ded f o r m
The dou bl e ex tr u ded f or m s c an ser v e the Car d Gu i de f u nc ti on.

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TI TLE: EMBOSS ( #0 7)

DESCRI P TI ON: An Em boss i s a dep r essi on or a dr awi ng to a shal l ow dep th on sheet

m etal su r f ac e. An em boss u su al l y wi l l be def i ned by a sp ec i al hei g ht.

DESI GN GUI DELI NE: The m ax i m u m hei g ht of an em boss i s di r ec tl y r el ated to the m ater i al
u sed, the m ater i al thi c k ness, the em boss shap e.

1. Em boss wi th a f l at top su r f ac e and c oni c al dep r essi on: The m ax i m u m hei g ht of an Em boss
i s eq u al to f i v e ti m es the m ater i al thi c k ness. The r ec om m ended tap er ang l e i s 45°.

EMBOSS w i t h Fl a t t o p s u r f a c e

H (m ax i m u m ) = 5T, R (m i ni m u m ) = T,
A (r ec om m ended) = 45°, R0 (r ec om m ended) = m i n r adi u s
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: em boss
hei g ht (H), base r adi u s (R), ang el (A), i nsi de r adi u s (R0).

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2. Em boss wi th ex tr u ded hol e and c oni c al dep r essi on: The m ax i m u m hei g ht of an em boss i s
f i v e ti m es the m ater i al thi c k ness; the m i ni m u m wi dth (B) i s.059”.

EMBOSS w i t h Ex t r u ded h o l e

H (m ax i m u m ) = 5T
B (m i ni m u m ) = .059“
R0 (r ec om m ended) = m i n, R (m i ni m u m ) = T, A (r ec om m ended) = 90

Rec o m m en ded
GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: em boss
hei g ht (H), bay wi dth (B), base r adi u s (R), tap er ang el (A), i nsi de r adi u s (R0).

3. Em boss wi th Ti nner m an and c oni c al dep r essi on: The m ax i m u m hei g ht of an em boss i s
f i v e ti m es the m ater i al thi c k ness. The di am eter of the top su r f ac e shou l d be enou g h f or the
swi r l hol e sp ec i f i c ati on.

EMBOSS w i t h Ti n n er m a n

H (m ax i m u m ) = 5T, A (r ec om m ended) = 90

R (m i ni m u m ) = T, R0 (r ec om m ended) = 0
Rec o m m en ded
GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: em boss
hei g ht (H), base r adi u s (R), tap er ang el (A), i nsi de r adi u s (R0).

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4. Em boss wi th other shap es: The m ax i m u m hei g ht of an Em boss i s eq u al to f i v e ti m es the

m ater i al thi c k ness.

EMBOSS w i t h g en er a l s h a p e

H (m ax i m u m ) = 5T
R (m i ni m u m ) = 5T
R1 (m i ni m u m )= T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: em boss
hei g ht (H), base r adi u s (R1), i nsi de c or ner r adi u s (R).

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FEATURE P OSI TI ON

Em b o s s t o Em b o s s
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) between the m aj or
di am eter s of two em bosses ar e ten ti m es the m ater i al thi c k ness p l u s the em boss r adi i .

Em b o s s t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om the m aj or di am eter
of an em boss to a bend i s f i v e ti m es the m ater i al thi c k ness p l u s the bend r adi u s and p l u s
the Em boss r adi u s.

Em b o s s t o h o l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3a) f r om the m aj or di am eter
of an em boss to a hol e i s eq u al to f ou r ti m es the m ater i al thi c k ness p l u s the em boss
r adi u s.
To the sl ot hol e, the m i ni m u m r ec om m ended di stanc e (D3b) f r om the m aj or di am eter of
an em boss i s eq u al to f ou r ti m es the m ater i al thi c k ness p l u s the em boss r adi u s.

Em b o s s t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) f r om the m aj or di am eter
of an em boss to an edg e i s f ou r ti m es the m ater i al thi c k ness p l u s the em boss r adi u s.

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 10T + R1 + R2
D2 (m i ni m u m ) = 5T + R2 + R3
D3a (m i ni m u m ) = 3T + R1
D3b (m i ni m u m ) = 4T + R2
D4 (m i ni m u m ) = 4T + R2
Rec o m m en ded

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TI TLE: COI NI NG EDGE ( #0 8 )

DESCRI P TI ON: An edg e that i s c ham f er ed by a sp ec i al shap e i s c al l ed Coi ni ng edg e. It wi l l

r edu c e the shar p ness of an edg e.

DESI GN GUI DELI NE: The c oi ni ng edg e si z e i s .020” x 20
. The tol er anc e of the f eatu r e i s
+ / -.008”.

COI NI NG EDGE

S (m i ni m u m ) = .016”
S (m ax i m u m ) = 0.5T
A (m i ni m u m ) = 20

A (m ax i m u m ) = 45°
Rec o m m en ded
GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: the
c ham f er l eng th (S ), ang l e (A). The c oi ni ng edg e f eatu r e shou l d be a c ham f er .

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TI TLE: LANCE ( #1 2 )

DESCRI P TI ON: A Lanc e f or m has two ty p es: op en l anc e and c l osed l anc e. An op en l anc e i s the
c u tti ng and f or m i ng of the m ater i al that i s attac hed onl y on one end. A c l osed l anc e i s the c u tti ng
and f or m i ng of the m ater i al that i s attac hed on both ends.

DESI GN GUI DELI NE: Al thou g h r el i ef i s not nec essar y , u si ng r el i ef i s a g ood desi g n p r ac ti c e f or
the l anc e f eatu r e i f p ossi bl e.

1. Cl osed l anc e f or m : the m i ni m u m wi dth of a c l osed l anc e i s eq u al to two ti m es the m ater i al

thi c k ness or .125”, whi c hev er i s g r eater ; the m ax i m u m hei g ht i s eq u al to f i v e ti m es the m ater i al
thi c k ness at a 45° ang l e (or f u l l r adi u s).

2. O p en l anc e f or m : the m i ni m u m wi dth of op en l anc e i s eq u al to two ti m es the m ater i al thi c k ness

or .125”, whi c hev er i s g r eater ; the m i ni m u m hei g ht i s eq u al to thr ee ti m es the m ater i al thi c k ness
or .144”, whi c hev er i s g r eater .

CLOSED LANCE OP EN LANCE

Lanc e (shear i ng ) Lanc e (shear i ng )

W (m i ni m u m ) = 2T, or .125“, whi c hev er i s W (m i ni m u m ) = 2T, or .125“, whi c hev er i s
g r eater g r eater
H (m ax i m u m ) = 5T, H (m i ni m u m ) = 3T, or .144“, whi c hev er i s
A (r ec om m ended) = 45° g r eater

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: l anc e
hei g ht (H), l anc e wi dth (W), ang l e (A).

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Du e to the p ossi bl e bu r r that wi l l be c r eated du r i ng shear i ng , esp ec i al l y f or thi c k er m ater i al , i t i s

r ec om m ended to u se r el i ef as dep i c ted i n the p i c tu r es bel ow.

P REFERRED LANCE FORM

Lanc e (wi th r el i ef ) Lanc e (wi th r el i ef )

Rec o m m en ded Rec o m m en ded

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FEATURE P OSI TI ON

La n c e t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) to the edg e i s:
In a p ar al l el p l ane:
The di stanc e (D1a) f r om the op en l anc e i s eq u al to f i v e ti m es the m ater i al thi c k ness.
The di stanc e (D1b) f r om the c l osed l anc e i s eq u al to f ou r ti m es the m ater i al thi c k ness.
In a p er p endi c u l ar p l ane:
The di stanc e (D1c ) f r om the c l osed l anc e i s 2.5 ti m es the m ater i al thi c k ness/

La n c e t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om the i nner su r f ac e of a
bend to the l eadi ng edg e of the l anc e i s:
In a p ar al l el p l ane:
The m i ni m u m di stanc e (D2a) f or an op en l anc e i s eq u al to f ou r ti m es the m ater i al thi c k ness
p l u s the r adi u s of the bend;
The m i ni m u m di stanc e (D2c ) f or a c l osed l anc e i s eq u al to thr ee ti m es the m ater i al thi c k ness
p l u s the r adi u s of the bend;
In a p er p endi c u l ar p l ane:
The m i ni m u m di stanc e (D2b) f or an op en l anc e i s eq u al to f ou r ti m es the m ater i al thi c k ness
p l u s the r adi u s of the bend;
The m i ni m u m di stanc e (D2d) f or c l osed l anc e i s eq u al to ei g ht ti m es the m ater i al thi c k ness
p l u s the r adi u s of the bend.

La n c e t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) that a l anc e shou l d be f r om
the edg e of a hol e i s thr ee ti m es the m ater i al thi c k ness.

La n c e t o La n c e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between two l anc es i s:
In the di r ec ti on of two si de-by -si de l anc es: the di stanc e (D4a) i s eq u al to f i v e ti m es the
m ater i al thi c k ness.
In the di r ec ti on of two f ac e-to-f ac e l anc es: the di stanc e (D4b) i s eq u al to f ou r ti m es the
m ater i al thi c k ness.

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Fea t u r e P o s i t i o n

D1a (m i ni m u m ) = 5T
D1b (m i ni m u m ) = 4T
D1c (m i ni m u m ) = 2.5T
D2a (m i ni m u m ) = 4T + R
D2b (m i ni m u m ) = 4T + R
D2c (m i ni m u m ) = 3T + R
D2d (m i ni m u m ) = 8T + R
D3a (m i ni m u m ) = 3T
D3b (m i ni m u m ) = 3T
D4 (m i ni m u m ) = 5T
D5 (m i ni m u m ) = 4T
Rec o m m en ded

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La n c e f o r m s w i t h a n ex t r u ded h o l e

La n c e ( o p en ) w i t h Ex t r u ded h o l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om the i nsi de su r f ac e of a bend
to the ex tr u ded hol e (the m aj or di am eter of a ex tr u si on) i s eq u al to two ti m es the m ater i al
thi c k ness,
The m i ni m u m di stanc e (D2) f r om the edg e to the m aj or di am eter of an ex tr u ded hol e i s eq u al to
2.5 ti m es the m ater i al thi c k ness.

LANCE( o p en ) w i t h Ex t r u ded h o l e

D1 (m i ni m u m ) = 2T, D2 (m i ni m u m ) = 2.5T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: di stanc e
f r om bend (D1), di stanc e f r om edg e (D2) and ex tr u si on i nsi de (or ou tsi de) di am eter .

La n c e ( c l o s ed) w i t h Ex t r u ded h o l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D) f r om a bend to the ex tr u ded hol e
(the m aj or di am eter of the ex tr u si on) i s eq u al to 2.5 ti m es the m ater i al thi c k ness.

LANCE( c l o s ed) w i t h Ex t r u ded h o l e

D (m i ni m u m ) = 2.5T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: di stanc e
f r om bend (D).

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TI TLE: HOOK ( #1 4)

DESCRI P TI ON: A Hook i s an op ened l anc e f or m on the sheet m etal su r f ac e; a hook al way s
ser v es f or a hook bef or e two c om p onents ar e f i x ed.

DESI GN GUI DELI NE: The m i ni m u m wi dth (W) of Hook i s eq u al to two ti m es the m ater i al
thi c k ness or .125”, whi c hev er i s g r eater . The r ec om m ended op en ang l e i s 30 °; the m i ni m u m
l eng th (L) of an end f l ang e i s 2.5 ti m es the m ater i al thi c k ness.
Addi ng r el i ef f or the hook f eatu r e i s r ec om m ended.

HOOK

W (m i ni m u m ) = 2T
L (m i ni m u m ) = 2.5T
A (r ec om m ended) = 30 °
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: O p en
ang l e (A), end f l ang e l eng th (L), hook hei g ht (H), hook wi dth (W).

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FEATURE P OSI TI ON

Ho o k t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) to the edg e i s eq u al to
f i v e ti m es the m ater i al thi c k ness.

Ho o k t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) to the i nsi de su r f ac e of a
bend i s eq u al to f i v e ti m es the m ater i al thi c k ness p l u s the r adi u s of a bend.

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 5T
D2 (m i ni m u m ) = 5T + R
Rec o m m en ded

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TI TLE: RI B ( #1 5 )

DESCRI P TI ON: A Ri b i s a c y l i ndr i c al dep r essi on; i t i s u su al l y u sed f or the p u r p ose of

str eng theni ng or sti f f eni ng a sheet m etal su r f ac e.

DESI GN GUI DELI NE: The m ax i m u m i nsi de r adi u s (R) of a r i b i s eq u al to thr ee ti m es the
m ater i al thi c k ness; the m ax i m u m dep th i s eq u al to the i nsi de r adi u s, or eq u al to the i nsi de
wi dth. The l eng th of a r i b i s not any c onstr ai nts.

RI B

R (m ax i m u m ) = 3T, H (m ax i m u m ) = 3T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: Ri b
hei g ht (H), Ri b wi dth (W), Ri b i nsi de r adi u s (R).

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FEATURE P OSI TI ON

Ri b t o Ho l e
Des i g n Gu i del i n e: the m i ni m u m r ec om m ended di stanc e (D1) that the c enter l i ne of a r i b
shou l d be f r om the edg e of a hol e i s two ti m es the m ater i al thi c k ness p l u s the r adi u s of
the r i b.

Ri b t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) that a r i b shou l d be f r om
the edg e i s:
In a p er p endi c u l ar p l an (D2a): thr ee ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of
the r i b.
In a p ar al l el p l ane (D2b): si x ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of the r i b.

Ri b t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) that a r i b shou l d be f r om
a bend i s:
Wi th bend p er p endi c u l ar to the r i b: two ti m es the m ater i al thi c k ness p l u s the i nsi de
r adi u s of the r i b, p l u s the r adi u s of the bend.
Wi th bend p ar al l el to the bend, thi s r i b g eom etr y i s u su al l y r edu ndant.

Ri b t o Ri b
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between two p ar al l el r i bs
i s eq u al to ten ti m es the m ater i al thi c k ness p l u s the r adi u s of eac h r i b.

Fea t u r e P o s i t i o n

D1 (m i ni m u m )= 2T + R1
D2a (m i ni m u m ) = 3T + R1
D2b (m i ni m u m ) = 6T + R1
D3 (m i ni m u m )= 2T + R1 + R2
D4 (m i ni m u m )= 10T + R1
Rec o m m en ded

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TI TLE: SEMI -SHEAR ( #1 6)

DESCRI P TI ON: A S em i -shear i s a bl i nd hol e that i s p u nc hed on the sheet m etal su r f ac e.

DESI GN GUI DELI NE: The m ax i m u m dep th of the sem i -shear i s eq u al to one-hal f the m ater i al
thi c k ness.
If the m ater i al thi c k ness i s l ess than .031i n (0.8m m ), i t i s str ong l y r ec om m ended not to u se
sem i -shear f eatu r e.

Sem i -s h ea r

H (m ax i m u m ) = T/ 2
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: sem i -
shear hei g ht (H), di am eter (D).

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FEATURE P OSI TI ON

Sem i -s h ea r t o Fo r m
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om the edg e of a sem i -
shear to a f or m i s thr ee ti m es the m ater i al thi c k ness p l u s the f or m r adi u s.

Sem i -s h ea r t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om the edg e of a sem i -
shear to a bend i s two ti m es the m ater i al thi c k ness p l u s the bend r adi u s.

Sem i -s h ea r t o Sem i -s h ea r
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) between the sem i -shear s
i s eq u al to thr ee ti m es the m ater i al thi c k ness.

Sem i -s h ea r t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between edg es of two
sem i -shear s i s eq u al to thr ee ti m es the m ater i al thi c k ness.

Sem i -s h ea r ( l o n g er ) t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D5) f r om the edg e of a l ong
sem i -shear to a bend i s di r ec tl y p r op or ti onal to the l eng th of the sem i -shear , m ater i al
thi c k ness and the r adi u s of the bend.

Fea t u r e P o s i t i o n

L: l eng th of S em i -shear

D1 (m i ni m u m ) = 3T + R2
D2 (m i ni m u m ) = 2T + R1
D3 (m i ni m u m ) = 3T
D4 (m i ni m u m ) = 3T

When L i s l ess than 1.0“ then D5 (m i ni m u m ) = 2.5T + R

When L i s 1.0” to 2.0” then D5 (m i ni m u m ) = 3T + R
When L i s ov er 2.0” then D5 (m i ni m u m ) = 3.5T + R
Rec o m m en ded

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TI TLE: RAI SED LETTERS I CON ( #1 7)

DESCRI P TI ON: A Rai sed l etter i c on i s f or m ed on the sheet m etal su r f ac e.

DESI GN GUI DELI NE: The r ec om m ended hei g ht of a r ai sed l etter i c on f eatu r e i s eq u al
to .020”.

RAI SED LETTERS I CON

H (r ec om m ended) = .020”
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D m odel c an be c r eated by sem i -shear f eatu r e. The
hei g ht of l etter s c an be set by .020”.

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TI TLE: DI MP LE ( #1 8 )

DESCRI P TI ON: The Di m p l e i s a sp her i c al dep r essi on i n the sheet m etal .

DESI GN GUI DELI NE: The ou tsi de di am eter of the Di m p l e shou l d be eq u al to, or l ess than,
si x ti m es the m ater i al thi c k ness, to a dep th eq u al to, or l ess than, f ou r ti m es the m ater i al
thi c k ness.

DI MP LE

D (m ax i m u m ) = 6T, H (m ax i m u m ) = 4T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: Di m p l e
hei g ht (H), di m p l e ou tsi de di am eter (D).

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FEATURE P OSI TI ON

Di m p l e t o Di m p l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) between two di m p l es
shou l d be thr ee ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of both di m p l es.

Di m p l e t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2 m easu r ed f r om the c enter
of the di m p l e) that a di m p l e shou l d be f r om a hol e i s thr ee ti m es the m ater i al thi c k ness
p l u s the r adi u s of the di m p l e.

Di m p l e t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3 m easu r ed f r om the c enter
of the di m p l e) that a di m p l e shou l d be f r om an edg e i s thr ee ti m es the m ater i al thi c k ness
p l u s the i nsi de r adi u s of the di m p l e.

Di m p l e t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4 m easu r ed f r om the c enter
of the di m p l e) that a di m p l e shou l d be f r om a bend i s two ti m es the m ater i al thi c k ness
p l u s the i nsi de r adi u s of the di m p l e p l u s the r adi u s of the bend.

Fea t u r e P o s i t i o n

D1 (m i ni m u m )= 3 T + R2 + R3
D2 (m i ni m u m )= 3 T + R2
D3 (m i ni m u m )= 3 T + R2
D4 (m i ni m u m )= 2 T + R1 + R2
Rec o m m en ded

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TI TLE: STAMP I NG I CONS ( #1 9 )

DESCRI P TI ON: A S tam p i ng i c ons i s u sed f or showi ng the p ar t nu m ber , l abel p osi ti on,
di r ec ti on i c on or som e other i nf or m ati on on the sheet m etal su r f ac e.

DESI GN GUI DELI NE: The r ec om m ended dep th of a stam p i ng f eatu r e i s eq u al to .008”, the
r ec om m ended wi dth of a stam p i ng i c on i s eq u al .008”; f or the tex t i c on (p ar t nu m ber ), the
hei g ht of tex t i s eq u al to .118”; the wi dth-hei g ht r ati o of tex t i s 0.8.

STAMP I NG I CON

D (r ec om m ended) = .008” (REF)

Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d be c l ear l y i ndi c ated the tex t hei g ht and
ap p r ox i m ate l oc ati on.

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FEATURE P OSI TI ON

St a m p i n g I c o n t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D) f r om the i nsi de su r f ac e of
a bend to the S tam p i ng Ic on i s eq u al to f ou r ti m es the m ater i al thi c k ness p l u s the r adi u s
of a bend.

Fea t u r e P o s i t i o n

D (m i ni m u m ) = 4T + R
Rec o m m en ded

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TI TLE: CARD GUI DE FORM ( #2 2 )

DESCRI P TI ON: A Car d g u i de f or m i s a f or m on the sheet m etal su r f ac e that ser v e the

p u r p ose of g u i di ng a sl i di ng c ar d.

DESI GN GUI DELI NE: The m ax i m u m l eng th of a c ar d g u i de f or m i s eq u al to 5.00” (4.00” f or

S / T). The m i ni m u m r ec om m ended op eni ng ang l e i s eq u al to 15
.

CARD GUI DE FORM

A (m i ni m u m ) = 15

L (m ax i m u m ) = 5.00” (4.00” f or S / T)
Rec o m m en ded
GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: Car d
g u i de f or m op en ang l e (A), g u i de f or m l eng th (L), g u i de f or m bottom wi dth (W).

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FEATURE P OSI TI ON

Ca r d g u i de f o r m t o Co u n t er s i n k Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om the m aj or di am eter
of the c ou nter si nk hol e to the c ar d g u i de f or m i s f ou r ti m es the m ater i al thi c k ness.

Ca r d g u i de f o r m t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om the f or m c enter l i ne
i s f i v e ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of the bend, (The di stanc e c an
be r edu c ed i f addi ng r el i ef (sl ot) on the bend.)

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 4T
D2 (m i ni m u m ) = 5T + R
Rec o m m en ded

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TI TLE: ROUND HEM ( #2 3)

DESCRI P TI ON: A r ou nd hem i s a c l osed hem f eatu r e f or m ed ar ou nd the ex i sti ng edg e of a

hol e on the sheet m etal su r f ac e.

DESI GN GUI DELI NE: The m i ni m u m r ec om m ended l eng th of the r etu r n f l ang e i s eq u al to
thr ee ti m es the m ater i al thi c k ness. The m i ni m u m r ec om m ended wi dth of the hem g eom etr y i s
eq u al to two ti m es l eng th of f l ang e p l u s thr ee ti m es the m ater i al thi c k ness. The g eom etr y of
thi s f eatu r e shou l d be obr ou nd.

ROUND HEM

H (m i ni m u m ) = 3T
W (m i ni m u m ) = 2H + 3T
R = f u l l r ou nd g eom etr y
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: Hem
r etu r n f l ang e l eng th (H), g eom etr y wi dth (W), g eom etr y r adi u s (R).

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FEATURE P OSI TI ON

Ro u n d h em t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om the i nsi de su r f ac e of
a bend i s thr ee ti m es the m ater i al thi c k ness.

Ro u n d h em t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om an edg e i s ei g ht
ti m es the m ater i al thi c k ness.

Ro u n d h em t o Sl o t
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) f r om a r ec tang u l ar hol e
edg e i s di r ec tl y r el ated to the l eng th of the sl ot and the m ater i al thi c k ness..

Ro u n d h em t o Fo r m
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) f r om the f or m i s ei g ht
ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 3T
D2 (m i ni m u m ) = 8T

When L i s l ess than 2.0“ then D3 (m i ni m u m ) = 8T

When L i s ov er 2.0” then D3 (m i ni m u m ) = 12T

D4 (m i ni m u m ) = 8T
Rec o m m en ded

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 Sheet Metal Design Guidelines E x tr uded H o le F o x c o nn . do c _ r ev . 0 1

TI TLE: EX TRUDED HOLE ( #2 4)

DESCRI P TI ON: Ex tr u di ng an ex i sti ng hol e or p i er c i ng and ex tr u di ng a hol e i n sheet m etal i s

c al l ed an Ex tr u ded hol e.

DESI GN GUI DELI NE: The hol e di am eter of the ex tr u ded hol e i s based u p on sp ec i f i c desi g n
r eq u i r em ents. The m ax i m u m hei g ht of ex tr u ded hol e i s l ess than hal f of the hol e di am eter (as
an ex am p l e, the m ax i m u m hei g ht f or M3 ex tr u ded hol e i s .059”)

EX TRUDED HOLE

H (m ax i m u m ) = M / 2 (M i s thr eaded sp ec )
Rec o m m en ded
GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on:
ex tr u si on hei g ht (H), i nsi de di am eter (d), tap p i ng sp ec (M).

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 Sheet Metal Design Guidelines E x tr uded H o le F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Ex t r u ded h o l e t o Ex t r u ded h o l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) between two ex tr u ded
hol es (f r om the m aj or di am eter of eac h ex tr u si on) i s f ou r ti m es the m ater i al thi c k ness.

Ex t r u ded h o l e t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) that the m aj or di am eter
of an ex tr u ded hol e shou l d be f r om an edg e i s thr ee ti m es the m ater i al thi c k ness.

Ex t r u ded h o l e t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) that the m aj or di am eter
of an ex tr u ded hol e shou l d be f r om a bend i s thr ee ti m es the m ater i al thi c k ness p l u s the
bend r adi u s.

Ex t r u ded h o l e t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) that the m aj or di am eter
of an ex tr u ded hol e shou l d be f r om a hol e i s thr ee ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1 (m i ni m u m )= 4T
D2 (m i ni m u m )= 3T
D3 (m i ni m u m )= 3T+ R
D4 (m i ni m u m )= 3T
Rec o m m en ded

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 Sheet Metal Design Guidelines T hr ead f o r m F o x c o nn . do c _ r ev . 0 1

TI TLE: THREAD FORM ( #2 5 )

DESCRI P TI ON: A Thr ead f or m i s a swi r l dep r ess on an ex i sti ng hol e. It al way s i s u sed f or
the sel f -tap p i ng sc r ew.

DESI GN GUI DELI NE: Mak e a note f or the f eatu r e to show i ts sp ec .

THREAD FORM

-
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d be c l ear l y i ndi c ated the f eatu r e by a thr ead
f or m ; the g eom etr y c an be c r eated by a f or m to show the thr ead di r ec ti on.

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 Sheet Metal Design Guidelines T hr ead f o r m F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Th r ea d f o r m t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om the i nsi de su r f ac e of
a bend to the m aj or di am eter of thr ead f or m i s eq u al to thr ee ti m es the m ater i al
thi c k ness p l u s the bend r adi u s:

Th r ea d f o r m t o Th r ea d f o r m
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) between two thr ead
f or m s i s eq u al to f i v e ti m es the m ater i al thi c k ness.

Th r ea d f o r m t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) f r om an edg e i s eq u al to
thr ee ti m es the m ater i al thi c k ness.

Th r ea d f o r m t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) f r om a hol e i s eq u al to
two ti m es the m ater i al thi c k ness.

Th r ea d f o r m t o Co u n t er s i n k
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D5) f r om the m aj or di am eter
of a c ou nter si nk i s eq u al to thr ee ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 3T + R
D2 (m i ni m u m ) = 5T
D3 (m i ni m u m ) = 3T
D4 (m i ni m u m ) = 2T
D5 (m i ni m u m ) = 3T
Rec o m m en ded

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 Sheet Metal Design Guidelines Gusset F o x c o nn . do c _ r ev . 0 1

TI TLE: GUSSET ( #2 6)

DESCRI P TI ON: A Gu sset i s a dep r essi on on the bend l i ne to ser v e f or sti f f eni ng a bend;

DESI GN GUI DELI NE: The g u sset i s r el ated to the m ater i al , the m ater i al thi c k ness and g u sset
r adi u s. The g u sset c an be set by a standar d g eom etr y to ser v e f or the sti f f eni ng f u nc ti on.

GUSSET

A1 (r ec om m ended) = 90

W (m i ni m u m ) = 2T
D (m ax i m u m ) = 2T
A2 (r ec om m ended) = 45

Rec o m m en ded
GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: Gu sset
dep th (D), Gu sset wi dth (W), Gu sset head ang l e (A1), Gu sset f or m ed ang l e (A2), Gu sset f or m
l eng th (L).

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 Sheet Metal Design Guidelines Gusset F o x c o nn . do c _ r ev . 0 1

Ti p s f o r t h e Gu s s et f ea t u r e.
Des i g n Gu i del i n e: The Gu sset wi l l r esu l t i n di stor ti on of a hol e i f the hol e and the g u sset ar e
i n-l i ne. Rec om m end to of f set g u sset and hol e.

GUSSET

D (r ec om m ended) = 3T Gu sset and a hol e ar e i n one l i ne

Rec o m m en ded No t Rec o m m en ded

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 Sheet Metal Design Guidelines Gusset F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Gu s s et t o Ho l e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) that a g u sset shou l d be
f r om the edg e of a hol e i s:
To a hol e (D1a): thr ee ti m es the m ater i al thi c k ness p l u s the r adi u s of the g u sset.
To a sl ot (D1b): f ou r ti m es the m ater i al thi c k ness p l u s the r adi u s of the g u sset.

Gu s s et t o Edg e
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) that a g u sset shou l d be
f r om an edg e i s:
In a p ar al l el p l ane (D2a): ten ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of the
g u sset.
In a p er p endi c u l ar p l ane (D2b): f ou r ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of
the g u sset.

Gu s s et t o Gu s s et
Des i g n Gu i del i n e: the m i ni m u m r ec om m ended di stanc e (D3) between two g u ssets i s
eq u al to ten ti m es the m ater i al thi c k ness p l u s the r adi u s of eac h g u sset.

Fea t u r e P o s i t i o n

D1a (m i ni m u m ) = 3T + W2/ 2
D1b (m i ni m u m ) = 4T + W1/ 2
D2a (m i ni m u m ) = 10T + W1/ 2
D2b (m i ni m u m ) = 4T + W1/ 2
D3 (m i ni m u m ) = 10T + W1/ 2 + W2/ 2
Rec o m m en ded

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 Sheet Metal Design Guidelines Sp o o n F o x c o nn . do c _ r ev . 0 1

TI TLE: SP OON ( #2 7)

DESCRI P TI ON: A sp oon i s a sp ec i al ty p e of op en l anc e f or m ed wi th a di m p l e on the

u nattac hed si de. A sp oon has a nar r ow nec k p ar t to ser v e the sp r i ng f u nc ti on when the
di m p l e i s p r essed.

DESI GN GUI DELI NE: The m i ni m u m wi dth of the di m p l e f l ang e f r om the edg e i s eq u al to 0.8
ti m es the m ater i al thi c k ness, or .032”, whi c hev er i s g r eater .

SP OON

S (m i ni m u m ) = 0.8T
Rec o m m en ded

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: S p oon
l eng th (L), S p oon nar r owest wi dth (W), S p oon hei g ht (H), S p oon f l ang e wi dth (S ).

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 Sheet Metal Design Guidelines Sp o o n F o x c o nn . do c _ r ev . 0 1

FEATURE P OSI TI ON

Sp o o n t o Ben d
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om a bend i s:
In a p ar al l el di r ec ti on, the m i ni m u m di stanc e (D1a) i s eq u al to f ou r ti m es the m ater i al
thi c k ness p l u s the r adi u s of the bend;
In a p er p endi c u l ar di r ec ti on, the m i ni m u m di stanc e (D1b) i s eq u al to thr ee ti m es the
m ater i al thi c k ness p l u s the r adi u s of the bend.

Sp o o n t o Sp o o n
Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) between the sp oons i s
thr ee ti m es the m ater i al thi c k ness.

Fea t u r e P o s i t i o n

D1a (m i ni m u m ) = 4T + R
D1b (m i ni m u m ) = 3T + R
D2 (m i ni m u m ) = 3T
Rec o m m en ded

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