Flat pattern → bend table → DXF → CNC. The four-step chain that gets a luminaire body off the screen, onto the brake, and out of the shop without three trial parts.
Model the part as 3D folded; SolidWorks tracks bend allowance per the K-factor in your bend table. Flat pattern is auto-generated, not redrawn from scratch.
Library of stamped features that drop into the flat. They show on both the 3D model and the DXF. Manual lofts cost hours per part, forming tools cost seconds.
Two flange tools, two jobs. Mitre flange wraps a perimeter (an enclosure rim). Edge flange adds a single bend. Mixing them up models parts that won't fold.
Configurations let you save a flat-only DXF for the laser, a folded STEP for the assembly, and an isometric PDF for QA. One model, three deliverables.
Numbers that decide whether the cut blank folds to size.
| Material | K-factor (typical) | Min bend radius |
|---|---|---|
| DKP cold-rolled steel | 0.42 - 0.44 | 1× thickness |
| Galvanised steel (HDG) | 0.40 - 0.43 | 1× thickness |
| 304 stainless | 0.41 - 0.45 | 1.5× thickness |
| 316 stainless | 0.41 - 0.45 | 1.5× thickness |
| 6063-T5 aluminium | 0.33 - 0.40 | 1× thickness |
| 5052 aluminium | 0.33 - 0.40 | 1× thickness |
| 5083 marine ALU | 0.33 - 0.40 | 2× thickness |
The model unfolds the same way every time. The shop tool dictates K-factor, calibrate to it.
Calibrate K-factor by material and thickness on your specific press brake, then save it in a SolidWorks bend table. Every new part references the table; a tool change updates one number, not 200 parts.
Spec inside dimensions for enclosures where fit matters internally (cards, modules). Spec outside for fit against external surfaces. Write the choice into the title-block standard, mixing on one drawing causes 5 mm errors at assembly.
A closed hem adds ~1 sheet thickness back; an open hem adds ~2×. These add up across 4-edge boxes. Spec the hem clearly in the flatten dimensions, not just the formed view.
Optimize the flat for material yield: rotate parts so longest dimension aligns with sheet direction, allow common-edge cuts where geometry permits. Saves 8-15% on raw stock per job.
SolidWorks form tools deform the material; extrudes remove it. Get this wrong and the flat pattern shows a hole instead of a louver. Form tools come in the design library, use them.
Sheet-metal designs unfold to laser-cut and bend-ready DXF directly from SolidWorks. K-factors calibrated to our Trumpf and Amada brakes, flatten once, bend right first time.
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