Sheet metal parts (47 entries)

Using standard sheet metal bending machinery typically reserved for metal, a complex 3D structure was formed from a single, highly brittle 1 mm plastic sheet solely through multiple precision bending operations. Because plastic fractures easily and exhibits a distinct springback behavior unlike metal, delicate control of tonnage and bending angles is required. By carefully observing the material's behavior, consistent and high-precision sequential bends were achieved. When folding a intricate form from a single sheet, slight dimensional deviations after each bend can lead to overall distortion; therefore, precise blank layout calculations and bending sequences were thoroughly optimized to create a flawless 3D geometry without dedicated tooling. This project serves as a demonstration of applying sheet metal craftsmanship to non-metallic materials and highlights new potential for low-volume production.