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Sheet Metal · Lesson 5: Complex shapes

Swept flanges, lofted bends (hoppers, transitions) and curved edge flanges.

Lesson goal

Model plate work parts beyond simple bending: swept profiles, transitions and flanges on curved edges.

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3 videos

✎

1 exercise

Advanced

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Prerequisite: Lessons 2 and 3

1. Watch the videos

Dassault Systèmes videos hosted on MySolidWorks: they open in a new tab and a free account is enough. Watch them in order.

Swept Flange in Sheet MetalVideo 1▶Swept Flange in Sheet MetalSweep an open profile along a path: cable trays, frames, guards.↗ Lofted Sheet MetalVideo 2▶Lofted Sheet MetalCreate a transition between two profiles, such as a hopper or a square to round.↗ Curved Edge FlangesVideo 3▶Curved Edge FlangesAdd an edge flange along a curved edge.↗

2. Key takeaways

1

The Swept Flange follows a path with an open profile: handy for cable trays and frames.

2

The Lofted Bend connects two open profiles; there are two methods: Bent (facets and bends, exact flat pattern) or Formed (smooth surface, approximate flat pattern).

3

The Edge Flange also accepts curved edges, as long as the starting face remains planar.

Tip

For a hopper made by a fabricator on a press brake, choose the Bent method: the flat pattern matches what they will actually produce.

3. Do the exercise

Model a hopper in 2 mm sheet:

  • 300 × 200 mm rectangular inlet
  • Ø 120 mm round outlet, 250 mm lower
  • Bent method, with a gap for the flat pattern
✓To check: The flat pattern is in one piece and can be cut from a standard sheet size.

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