Sheet metal rule treating corners different

[Phil_estep]

Hi all, Ive been scratching my head all day trying to figure out why my ouside miter flanges on sheet metal now have a buldge on the flange keeping flat patterns from being made. Ive had the same sheet metal rule for over a year and this just started happening. Most of my knowlege on setting up sheet metal was from trial under fire but had no issues until today with these same type of bends

[Frederick_Law]

Because the radius and gap is too tight.  The radius part is overlapping.

Inside radius should be atleast thickness.  Unless you're forming the bends.

Try 0.01 on corner gap.

I can't edit 2024 file.

[Phil_estep]

shows the same at .01. i have my bend radius at .001, corner gaps for both flanges @ .01.

[Frederick_Law]

Not all gap at 0.01.

[Phil_estep]

here is everything at .01 with a bend radius of .001. Miter/seam gap is showing no difference if i use .01 or 1.0. im attempting to find an older part with the same profile. it used to do squared off 90 degree bends to the outside and the miter was made automatically on the flat plane, not twisting the corners together keeping an overlaping feature.  Is it possible a something higher up is over riding rules?

[Frederick_Law]

Make it bigger enough so the bends doesn't touch.

[DavidKuhlmann]

Here is my attempt in Inventor 2025.  I changed some of the gap settings. (edit and the corner settings).

[Frederick_Law]

2023 File attached.

[Phil_estep]

Making it .10 took the auto miter out.  which isnt to much to draw in real quick but this corner now with the larger gap is how my old mitered corners looked. after the bend it would start the auto miter on the flat side.  Ive used the same gap in fusion and inventor for over a year which was alway tight corners for fusing but im assuming ive messed with a setting somewhere accidentally now. 

[Phil_estep]

i loaded yours, i looked good. I changed this thickness to a smaller gauge and it looks perfect. I tried to replicate it with all ytour settings to no avail

[Phil_estep]

i loaded yours, i looked good. I changed this thickness to a smaller gauge and it looks perfect. I tried to replicate it with all ytour settings to no avail

[Frederick_Law]

Gap set to 0.0001.

[DavidKuhlmann]

The Gap Settings in your individual Flange features were overridden, I changed them to the default values and changed the 2 Bend Relief Shape to Tear to close the bottom corners.

[Frederick_Law]

From 0.0001" to 1" gap, nothing failed.

[Phil_estep]

On my, and my co workers pc,'s. Nothing changed. They didn't move apart even with large bend radius's below. But I also wasn't able to create someone's part copying their settings.  I'll remote in and download your .001 gap part shortly and see if I can replicate that.  No issues making this preciously . if you load my part, does it keep all of it's settings or do yours override it?

[DavidKuhlmann]

My loading your part did not override it's settings, I changed them in the copy that I saved of your part.  I deleted your parts Flange3, tried a couple of other ideas, and ended up replacing your Flange3 with Flange4.