topic Re: Different bending radius on same sheet metal part in Fusion Design, Validate & Document Forum

Different bending radius on same sheet metal part

GC_CC — Mon, 02 Feb 2026 11:11:54 GMT

Hello,

I modelled a sheet metal piece, but it has different inside bend radius.

I used the same stainless steel rule with a thickness of 3mm and an inside radius of 4.5mm.

The down bends are inside radius 4.5mm and outside 7.5mm = correct

The up bends are inside radius 7.5mm and outside 10.5mm = wrong, should be 4.5mm and 7.5mm also.

This behaviour is new to me, I am afraid that the part won't bend correctly.

Can anyone explain me why this is and how I can fix it?

Thanks

Re: Different bending radius on same sheet metal part

jhackney1972 — Sun, 01 Feb 2026 22:26:18 GMT

You must have attached the wrong model. All inside radii are 4.5mm and all outside radii are 7.5mm.

Re: Different bending radius on same sheet metal part

a.laasW8M6T — Sun, 01 Feb 2026 22:56:39 GMT

@jhackney1972

Not these ones:

Re: Different bending radius on same sheet metal part

Warmingup1953 — Mon, 02 Feb 2026 15:28:18 GMT

It does appear that Side 1, Centre have different results to Side 2 but I think that is to be expected.

Re: Different bending radius on same sheet metal part

GC_CC — Mon, 02 Feb 2026 15:46:10 GMT

Interesting...

I chose side 2 in my original design and get these radius when I make a bend table (as I said all the down bends are OK):

When I switch to side 1 I get this table:

Almost all 4.5mm but one is 7.5mm... wierd

Update: When i choose Center I get all bends 4.5mm, so strange

Is there a way to solve this without having to draw it again

Re: Different bending radius on same sheet metal part

Warmingup1953 — Mon, 02 Feb 2026 16:10:22 GMT

Something weird is happening..If I swap to Side 1:

and the Drawing shows it is up to date even after I swap back to Side 2 Update the Flat Pattern and save. I'll have to have another look when time allows

Re: Different bending radius on same sheet metal part

johnsonshiue — Mon, 02 Feb 2026 21:37:05 GMT

Hi! I could be wrong but I think the Lofted Flange cannot guarantee consistent Bend Radius across the entire body. It depends on the faceting tolerance and the geometry. In this case, the upper left Bend on Side 1 has 7.5mm Bend Radius, because it transitions from a vertical line to an arc. 4.5mm does not offer enough room for such change. If you edit Sketch 5, trim off the arc a little bit, and add a short vertical segment, I believe the Bend at the corner will have 4.5mm Bend Radius.

Many thanks!

Re: Different bending radius on same sheet metal part

GC_CC — Fri, 06 Feb 2026 16:43:59 GMT

I designed the part again and used the lofted flange feature with orientation "Center".

I have the exact same overall dimentions, but now it used all inner radius of 4.5mm.

I don't really know why, but it worked. Thanks @Warmingup1953 for the hint.