topic Re: sheet metal issues with converging bends in Fusion Design, Validate & Document Forum

sheet metal issues with converging bends

rugalugs — Fri, 21 Nov 2025 23:25:40 GMT

hello,

i do a lot of sheet metal work in fusion and always struggle with converging bends,

the latest is a inlet manifold plenum , i usually start from a solid , shape it how i want , convert to a surface, apply fillets, thicken and convert to sheet metal , then flat pattern for my cnc router, but i always have troubles where 2 or more bends converge,

i have attaced a section that is giving me trouble to see how would be best to solve it,

i have tried the above method with no luck, i ahve tried lofting a flange (get a non planar issue and have check all the faces appear to be planar, ive tried rounded thicked with and without fillets,

how i have delt with it in the past is when its a surface i remove a section where the bends would meet and then go through the process to get it to a sheet metal part.

i am self taught but believe i am realativly proficient now but im hoping there is a easy solution or somthing i dont know about

any help would be appreciated

cheers

dave

Re: sheet metal issues with converging bends

kacper.suchomski — Sat, 22 Nov 2025 00:30:09 GMT

Cutouts should be added where surfaces intersect.

Re: sheet metal issues with converging bends

TheCADWhisperer — Sat, 22 Nov 2025 00:37:23 GMT

@rugalugs

You didn't indicate whether your thickness is to the inside or outside.

See Attached examples.

Re: sheet metal issues with converging bends

Warmingup1953 — Sat, 22 Nov 2025 00:59:30 GMT

A bit hard to tell just from the derived surface body but I fear this are won't fillet correctly. Can you share the original file?

EDIT attached is my close but no cigar play at it...It unfolds but errors on Flat Pattern but it shows my idea at the vertices.

Re: sheet metal issues with converging bends

rugalugs — Sun, 23 Nov 2025 21:25:06 GMT

hello, 🙂

yes that is how i have to get it to work but seemes quite tedius and was hoping there was a easier /faster solution for it

Re: sheet metal issues with converging bends

rugalugs — Sun, 23 Nov 2025 21:36:31 GMT

hello 🙂

thickness is usually outside

Re: sheet metal issues with converging bends

rugalugs — Sun, 23 Nov 2025 21:45:49 GMT

thanks for you help,

this baffles me aswel, i tray and do a lofted flange and it errors when i select all the lines, says non planar faces, but i can do more than half of the profiles, if it can do half why not both halves? i ahve also checked all faces appear to be planar

please see example

Re: sheet metal issues with converging bends

rugalugs — Sun, 23 Nov 2025 21:47:26 GMT

i would hvae thought too that when you convert it to sheet metal it would apply the sheet metal rules ect regarding corners and reliefs?

Re: sheet metal issues with converging bends

TheCADWhisperer — Sun, 23 Nov 2025 23:07:23 GMT

@rugalugs

Did you look at the files that I attached?

Your example doesn't make logical sense as it would be twisted.

Re: sheet metal issues with converging bends

rugalugs — Wed, 26 Nov 2025 22:25:14 GMT

hello,

yes i did look at your examples thankyou,

you are probably very right ,but i cant see how its twisted? if i remove a circle of the surfaces where the sections intersect/ clash everything works fine suggesting that its not twisted?, i can then fillet/thicken and convert to sheet metal.

i can then flat patternt ect and all good so i dont see why it errors when trying to do a lofted flange

ill attach the whole file im working on which i have now completed:)

this is how ive always got it done was just hoping there was a faster less tedius way to do it or that i dodnt know somehting to make it faster, if it would just do these reliefs automatically when converting to sheet metal, like it does when you do a lofted flange

cheers

🙂

dave