A Small Tip For Sheet Metal Design

A common oversight in sheet metal bending design: when a flange’s oblique (slanted) edge extends directly into the bend deformation zone, it causes distortion and poor bend quality.

As shown in the classic example (the first pic: original design), the slanted edge reaches the bend line, leading to deformation during forming.

Simple fix (the 2nd pic: improved design): Increase the flange height to provide a straight section (recommended >2x material thickness) before the slant begins. This ensures stable bending and avoids issues in the deformation zone.