topic Re: Sheet metal, relief shape gap in Inventor Forum

Sheet metal, relief shape gap

bnv5YBJX — Mon, 22 Dec 2025 11:33:28 GMT

Hi,

I have a weird situation and don't know the cause nor the good solution. When making a corner in sheet metal for a machine cover we used a large radius to make a smooth transition. While making the feature all looks like we want it (picture 1)

But after that it turns into a wide gap (picture 2). Also the flat pattern doesn't show the required curve to close the gap.
Tried al I know (chnging default radius, changing relief shape, miter gap etc.) Nothing worked. In the end unfolded, sketched surfaces, refolded. Looked "ok-ish" (opicture 3), this we can fix in the workshop.

Does anyone know what is going wrong and how to decently get this done?

Re: Sheet metal, relief shape gap

CCarreiras — Mon, 22 Dec 2025 11:42:27 GMT

Hi!

Sharing the part would help to find a solution... we can do nothing with images...

Re: Sheet metal, relief shape gap

bnv5YBJX — Mon, 22 Dec 2025 11:43:50 GMT

Made a simplified part to work it out, but system is the same.

Re: Sheet metal, relief shape gap

kacper.suchomski — Mon, 22 Dec 2025 15:11:46 GMT

You can do it manually:

(view in My Videos)

Re: Sheet metal, relief shape gap

johnsonshiue — Mon, 22 Dec 2025 21:49:28 GMT

Hi! This is a feature creation order issue. The problem is that the desirable 2-Bend Relief is overridden by a 3-Bend Relief. Unfortunately, there isn't an option called, "Preserve 2-Bend Relief." As a result, the 3-Bend Relief takes over and the relief shape changes.

Here is a simple workflow to avoid the behavior. Simply use the Rip command to remove the very first bend created by the Contour Flange. And create the Flange as usual. Then use the Bend command to connect the two flanges back together. Please take a look at the attached part.

Many thanks!

Re: Sheet metal, relief shape gap

bnv5YBJX — Tue, 23 Dec 2025 07:29:28 GMT

Hi, This was a solution I thought about also, surface modelling. But dismissed it as too much of a hassle.
Gives very good result though. If I need a very estethic pleasing part I would consider it. But as this is for a construction machine it is overkill.

Re: Sheet metal, relief shape gap

bnv5YBJX — Tue, 23 Dec 2025 07:31:10 GMT

Hi, Thanks for the solution. I see a proposal for improvement of the sheetmetal feature coming up. 😁