topic Sheet Metal - Edge not perpendicular to part in Fusion Design, Validate & Document Forum

Sheet Metal - Edge not perpendicular to part

Brysenk06 — Sat, 10 Jan 2026 03:50:08 GMT

I’m creating an angled extension to Body 1 in the attached model. I projected the geometry onto a sketch on Plane 1 at the desired angle and used the Lofted Flange tool to create the sheet metal body. Then I used Extrude to extend the other end up to the face of Plane 2.

When I do this, the resulting edge ends up parallel to Plane 2 instead of perpendicular to the face of Body 2. I’m assuming this happens because I used a solid extrude instead of a sheet metal feature.

If that’s the case, what sheet metal tool should I be using so the edge stays perpendicular to the face of Body 2 while still extending up to (and butting against) Plane 2?

Thanks in advance! All help is appreciated.

Re: Sheet Metal - Edge not perpendicular to part

Warmingup1953 — Sat, 10 Jan 2026 06:02:40 GMT

Rather than your question...All looks good up to here...what are you trying to create next?

Re: Sheet Metal - Edge not perpendicular to part

TheCADWhisperer — Sat, 10 Jan 2026 06:20:28 GMT

@Brysenk06 wrote:
I’m creating an angled extension to Body 1
to the face of Body 2.

@Brysenk06

A sheet metal Component should have only one body.

As indicated by @Warmingup1953 can you elaborate a bit about your Design Intent?

Re: Sheet Metal - Edge not perpendicular to part

kacper.suchomski — Sat, 10 Jan 2026 13:31:07 GMT

First method:

(view in My Videos)

Re: Sheet Metal - Edge not perpendicular to part

kacper.suchomski — Sat, 10 Jan 2026 13:39:08 GMT

Second method:

(view in My Videos)

Re: Sheet Metal - Edge not perpendicular to part

kacper.suchomski — Sat, 10 Jan 2026 13:42:39 GMT

Third method:

(view in My Videos)

Re: Sheet Metal - Edge not perpendicular to part

kacper.suchomski — Sat, 10 Jan 2026 18:11:50 GMT

Fourth method:

Use Loft Flange (as with the first solid) instead of Extrude. Classic tools for modeling flanges should not be used, as they are not optimized for modeling sheet metal that meets technological requirements.

As mentioned by previous speakers, avoid multi-body sheet metal. This will cause significant problems later in the design process. Develop a sound workflow and, from the outset, create separate components for all ultimately produced elements.

This applies to all of the above methods.

Re: Sheet Metal - Edge not perpendicular to part

johnsonshiue — Mon, 12 Jan 2026 16:40:32 GMT

Hi! There are multiple ways to create the normal cut on the Sheet Metal part, as illustrated by the experts. There is another way to do that by using Unfold/Refold. Unfold the body -> Extrude the planar faces and intersect the existing body. Lastly, refold it back.

Many thanks!