topic Re: Complex shet metal flange shapes workflow in Fusion Design, Validate & Document Forum

Complex sheet metal flange shapes workflow

sonnie_b — Sat, 14 Mar 2026 21:30:10 GMT

Proficient in Inventor but learning Fusion. I would like to create a complex shaped flange that uses an existing projected sheet metal geometry profile to produce the flange's shape. Is there a way to sketch on a flange and add material to that flange? Or, sketch the shape of the flange you desire and extrude the thickness while selecting the edge of the existing sheet metal part you want to combine with? In the attached pic, the edge with the red arrow is the bend edge and the sketch is the "flange" shape i desire. Maybe i just need some help with workflows. My Inventor work flows are not compatible.

Re: Complex shet metal flange shapes workflow

jhackney1972 — Sat, 14 Mar 2026 16:09:58 GMT

Please attach your model. If you do not know how to attach your Fusion 360 model follow these easy steps. Open the model in Fusion 360, select the File menu, then Export and save as a F3D or F3Z file to your hard drive. Then use the Attachments section, of a forum post, to attach it. If needed, ZIP a F3Z file.

Re: Complex shet metal flange shapes workflow

sonnie_b — Sat, 14 Mar 2026 16:29:33 GMT

My apologies, I thought this was a very elementary question and would not require attaching a model.

Re: Complex shet metal flange shapes workflow

sonnie_b — Sat, 14 Mar 2026 17:07:24 GMT

Attached in a post reply.

Re: Complex shet metal flange shapes workflow

jhackney1972 — Sat, 14 Mar 2026 17:28:27 GMT

Fusion does not have the ability to merge sheet metal bodies together so your flange has to be created and the profile shape cut from it. Model attached.

Re: Complex shet metal flange shapes workflow

sonnie_b — Sat, 14 Mar 2026 18:04:38 GMT

Thank you. That is basically the conclusion I came to through trial and error, but wanted to make sure I wasn't missing something and waste time learning that path if there was something easier or better. Looks like the bend reliefs need to be added manually, see attached. I could see this workflow possibly becoming problematic in certain situations if the bend reliefs are not automatically applied. Any alternative methods you can think of that might include the automatically applied bend reliefs? Maybe a flatten and fold approach or a top down approach, vs. my bottom up? I am just too new to Fusion sheetmetal and find myself frustratingly handcuffed using it compared to Inventor, so still trying to understand workflow limitations.

Re: Complex shet metal flange shapes workflow

TheCADWhisperer — Sat, 14 Mar 2026 19:06:30 GMT

@sonnie_b

(view in My Videos)

Re: Complex shet metal flange shapes workflow

sonnie_b — Sat, 14 Mar 2026 19:43:47 GMT

Thanks for the video, very helpful.

Re: Complex shet metal flange shapes workflow

SaeedHamza — Sat, 14 Mar 2026 20:48:24 GMT

Here is my way of doing it where I used a small trick of creating an extra flange to extend into a new one, so not sure if it's okay for your design or for sheetmetal work in general as I'm not an expert in that area, but it's something worth considering.

Re: Complex shet metal flange shapes workflow

sonnie_b — Sat, 14 Mar 2026 21:20:35 GMT

I included my technique in the attached part that I am, so far, happy with. It approximates nearly exactly a similar part I make in Inventor, which was my goal. I don't know if this is the most elegant or quickest. It took me some time, but understanding how to use the contour flange tool was the key, along with the tips learned from all your comments. Thanks for all the help

Re: Complex sheet metal flange shapes workflow

johnsonshiue — Mon, 16 Mar 2026 16:01:10 GMT

Hi! As experts have already illustrated, there are multiple ways to create the desirable geometry. Here is another solution. Basically, create a Face Flange using the profile. Then use Push/Pull to get some clearance at the bend zone. Lastly, use Revolve command to create the bend.

Many thanks!

Re: Complex sheet metal flange shapes workflow

sonnie_b — Tue, 17 Mar 2026 18:19:36 GMT

I see that and thanks for this solution. There are many ways to make the part, even without using the Sheetmetal tools.. The one problem I have with all of these methods is that the sheetmetal rules are abandoned or have to be manually applied when adding material to a flange. I am specifically referring to bend reliefs, but in your example the bend radius is set by the user, not the rule, and with no bend reliefs. Is there a suggestions forum? I looked but didn't see one.

Re: Complex sheet metal flange shapes workflow

johnsonshiue — Wed, 18 Mar 2026 19:23:04 GMT

Hi! Please start a new thread articulating the exact feature request. I will make sure the project team is aware of the request.

Many thanks!