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Sheet metal design involves cutting 2D flat parts—usually from aluminum or polycarbonate—and bending them to form rigid 3D structures. Common in professional manufacturing, this method brings high strength-to-weight ratios and sleek results to FTC when used with laser cutters, waterjets, or CNC routers.
Parts are designed in a flat form and cut from a sheet.
Bends are made with a brake, hand bender, or pliers (for thin plastic).
Holes, cutouts, and slots are added during cutting, enabling precise integration.
Strong and Lightweight: Folded edges reinforce structural stiffness.
Custom Fit: Integrate mounting points, wire routing, and geometry directly into part design.
Low Profile: Flat geometry makes it ideal for tight packaging.
Requires Planning: You must account for bend radii, reliefs, and K-factors (bend stretching).
Tooling Needed: Bending aluminum cleanly requires a brake.
Not Modular: Parts are purpose-built and difficult to reuse on other bots.
Use 5052 aluminum in 0.04–0.063" thickness for easy bending.
Design for single-direction bends to keep parts simple.
Avoid sharp 90° interior corners—use radiused slots to prevent stress cracks.
Polycarbonate sheet can be heat bent and is easier to prototype.
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