Being a major barrier to adopting 3D for most fabricators, converting legacy design data and migrating to an entire new design platform and processes is a challenge.

Sheet metal fabrication is a complicated process. Unlike solids, the design of sheet metal products starts with a 2D metal sheet, which is folded, bended, punched, welded and finally converted to the desired shape. A lot of engineering hours are often required in developing 2D flat patterns that go as DXF files in the CNC machine to make required cuts in the metal sheet.

More often, fabricators at the shop floor have to accommodate changes in the design to suit the tooling capabilities and DFM (Design for Manufacturability) requirements, which leads to change orders and eventually delays the development. While there is a widespread proliferation of advanced design tools, sheet metal sector is slow in adoption, and this is the major bottleneck in driving more productivity.

A survey from National Institute of Standards and Technology (NIST) which says that 90% of small manufacturers still rely on 2D processes shouldn’t surprise us then. The same survey suggests that implementing 3D can actually reduce the production time by 70%.

The question is why fabricators are still reluctant towards utilizing the 3D approach? The reasons are many, but the prominent ones include the inability to understand completely the benefits of using 3D CAD across all the product development stages, resistance to change as most of the designs are in 2D and for some, the end customers requirement is of 2D deliverables. What adds to their denial in adopting 3D is the need to train the existing resources, cost involved in purchasing the 3D software and migrating the existing legacy designs in 2D to 3D, that would unnecessarily disrupt the smooth production processes. While some of the reasons are completely valid, overcoming them is easy and the way forward to unlock more productivity right from concept through production.

3D CAD for Sheet Metal Fabrication

Adopting 3D CAD over 2D has multiple benefits, and should be incorporated right from the conceptual stages. With the ability to represent the product in three dimensions, communicating the design is much easier and eliminates the possibilities of errors or ambiguity. Conceptual models can quickly be transformed to manufacturing ready products, by performing assembly checks, DFM requirements and even analyze the functioning through simulations. CAD tools available today are essentially included with sheet metal design features, which further allow design engineers to quickly develop model in 3D, unfold and generate accurate 2D drawings with suitable bend allowances and features like beads, hems, chamfers, holes spacing, etc.

Creating sheet metal design in a parametric 3D environment means any update in the model automatically updates the drawings, BOMs (Bill of Materials) and cut lists, so that there remains a single source of truth across the development schedule. Having a 3D CAD model of the sheet metal component further allows performing necessary performance tests using CAE tools and reduce physical test trials and associated costs. It is with 3D CAD, that fabricators can generate photorealistic 3D renderings for marketing collaterals.

Migrating Legacy Design Data

Being a major barrier to adopting 3D for most fabricators, converting legacy design data and migrating to an entire new design platform and processes is a challenge. This however can be solved by filtering out the legacy data that’s more important for conversion and re-design other smaller or less important data from scratch in 3D whenever there is a need.

Further, CAD tools offer hybrid modeling approach which provides 2D integration, so that design engineers can work in different modes progressively, rather than working directly in 3D. Sheet metal fabricators can also seek assistance from engineering service providers who can help right from the beginning in the migration process without disrupting the ongoing fabrication tasks.

3D CAD opens up multiple opportunities for sheet metal fabricators in turning their processes more productive and in turn brings more efficiency and accuracy in developing products for the customers. Adopting 3D from concept through production not only eliminates errors in design communication but also enables fabricators to remain competent in a market that is moving towards becoming digital.

About Author:

Kashyap Vyas is an Engineer at Hi-Tech Engineering Services and holds a Master’s degree in Thermal Engineering with several research papers to his credit. He covers CAD and CAE topics for the engineering industry. His contributions are primarily focused on encouraging manufacturers and suppliers to adopt virtual product development tools to build efficient products with reduced time-to-market.