topic Re: Connecting 2 faces at different angles in sheet metal in Fusion Design, Validate & Document Forum

Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 01 Apr 2026 17:27:13 GMT

I am designing some trailing arm brackets with the help of a 3d scan mesh. The goal is to cut the brackets with cnc plasma and bend to shape. The brackets have two sheet metal faces at different angles that need to be joined. I have tried lofted flange in sheet metal, and Loft in solids with no success. The Loft function in solids worked to connect the two pieces of sheet metal but it wont allow me to create a flat pattern. The picture shows the angle differences and where they need to meet. Any help is greatly appreciated. Thank you

Re: Connecting 2 faces at different angles in sheet metal

jhackney1972 — Wed, 01 Apr 2026 16:26:02 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: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 01 Apr 2026 17:27:48 GMT

Model has been added to my original post

Re: Connecting 2 faces at different angles in sheet metal

TheCADWhisperer — Wed, 01 Apr 2026 18:53:33 GMT

@petrenc

See Attached.

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 01 Apr 2026 19:25:04 GMT

I was able to create that as well with lofted flange but not exactly what i'm looking for. Too many bends and aesthetically unpleasing.

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 01 Apr 2026 19:29:40 GMT

This is what im looking for which was created with loft in the solids toolbar. Only problem with this method is the intersecting piece becomes thinner than the other plates which goes against sheet metal rules and wont allow me to create flat pattern.

Re: Connecting 2 faces at different angles in sheet metal

TheCADWhisperer — Wed, 01 Apr 2026 21:13:17 GMT

@petrenc

That is not the file that you Attached here for reference.

You have a twist in the material.

You will have to use Meshmixer or Autodesk Inventor Professional - Unwrap function

align those edges such that the transition is planar rather than twisted.

I will give it a try when I get a chance.

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 01 Apr 2026 21:45:59 GMT

Correct, I tried attaching that image in the first post but the forum only allows 3 uploads. I felt the other 3 were more helpful.

And yes the two faces are not planar but if it is possible to complete the desired shape with loft or even a piece of paper then its definitely possible in fusion.

Based on my CAD(cardboard aided design), each top and lower flanges must have a different angle to accomplish it being cut out of a flat plate of steel. How to figure out those angles is beyond me. Maybe using bends instead of flanges?

I appreciate you giving this a shot!

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 01 Apr 2026 22:22:41 GMT

NVM I take back what i said about my ''CAD''. The top and bottom pieces dont have to be different angles on the connecting sides. Just the connecting piece has to have different lengths on each side. I dont know if im even making sense at this point. Might just be talking to myself at this point. lol

Re: Connecting 2 faces at different angles in sheet metal

TheCADWhisperer — Wed, 01 Apr 2026 22:32:24 GMT

@petrenc

See Attached.

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 01 Apr 2026 23:52:13 GMT

Fantastic!! Share your secrets!!

Re: Connecting 2 faces at different angles in sheet metal

TheCADWhisperer — Thu, 02 Apr 2026 00:27:52 GMT

@petrenc

No secrets - all steps are recorded in the Timeline.

We could also straighten these edges of Flat Pattern for manufacturing purposes but might not look as good in bent form.

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Sat, 04 Apr 2026 12:10:34 GMT

Thank you! Ive never used the surface tools and now I see how valuable they can be. I dont think theres a need to straighten the edges for manufacturing purposes as I will be cnc cutting it from sheet.

Thanks again! Problem solved!

Re: Connecting 2 faces at different angles in sheet metal

TheCADWhisperer — Sat, 04 Apr 2026 20:05:36 GMT

@petrenc

I hope you haven't made the part yet.

That was just my first attempt to understand the geometry.

In a few minutes I will post video of improvement on the geometry angles.

Q. What scanner did you use to can the part?

https://youtu.be/ms4MU7Y-qIo

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Tue, 07 Apr 2026 12:22:39 GMT

Im in the middle to sketching it still. I have the geometry figured out I think but having a hard time putting a fillet on the edges before converting to sheet metal.

Ill watch the video first and keep you updated.

The scan is from KIRI Engine app on my phone.

Re: Connecting 2 faces at different angles in sheet metal

TheCADWhisperer — Tue, 07 Apr 2026 16:54:31 GMT

Must Stitch the surfaces together before Fillet.

Re: Connecting 2 faces at different angles in sheet metal

navya_gelli — Wed, 08 Apr 2026 07:12:47 GMT

Hi @petrenc ,

Did the info from @TheCADWhisperer help answer your question?

If it did, it’d be great if you could click the "Accept Solution" button so others can easily find it too.

If you’re still needing more help, feel free to share an update here. The community will be happy to jump in with any next steps to help you get where you need to be.

Best,

Navya | Community Manager

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 08 Apr 2026 15:15:25 GMT

Yes there has been a solution to my problem. Thank you CADwhisperer!

Re: Connecting 2 faces at different angles in sheet metal

petrenc — Wed, 08 Apr 2026 15:17:21 GMT

This worked perfectly for me! Thank you so much!