Bend Reliefs in Sheet Metal Design

2025/09/19

3 minutes read

Bend Reliefs in Sheet Metal Design

Bending is a crucial part of sheet metal design and fabrication in order to form precise shapes that enhance functionality, strength and aesthetics of your custom parts and enclosures. It reduces welding and assembly needs, lowers costs by minimizing waste and increases versatility for various applications across industries.

Challenges During the Bending Process

During the bending process, the biggest worry is that the material will end up cracking. This often occurs when the stress concentration at the bend exceeds the material’s tolerance.

Another challenge is tearing or distortion at the edges of the material during bending, which often results in irregularities that compromise the structural integrity and visual quality of the design.

What are Bend Reliefs?

One way to overcome this issue is by using bend reliefs. Bend reliefs are small intentional cuts placed at the ends of bends in sheet metal designs to prevent tearing, cracking, or warping during the bending process. They are also known as relief cuts and are used in nearly every custom design.

They are especially important when a bend ends near an edge, a tab, or a corner where the material would otherwise be stretched excessively. By relieving concentrated stress in these areas, bend reliefs allow the sheet to bend cleanly and maintain dimensional accuracy.

CAD drawing displaying material thickness and the bend relief width
The relief width should match or slightly exceed the material thickness

Why Bend Reliefs are Useful

The main purpose of using bend reliefs is to prevent cracking and tearing. Bend reliefs provide a break in the material so it doesn’t stretch too far during bending. This is especially important for parts with narrow flanges or tight bends close to edges.

As mentioned earlier, bend reliefs reduce warping as it ensures that the material has a path to deform without bunching or bulging at the bend edge.

Bend reliefs also protect features near the bend. They do so by isolating bending stress from nearby holes or slots, preserving dimensional integrity.

Finally, bend reliefs also improve aesthetics as you get cleaner corners and less visual distortion. This is important for enclosures and parts with visible flanges.

Guidelines for Designing Bend Reliefs

To achieve good results, make sure the relief width matches or slightly exceeds the material thickness. The bend depth should extend just beyond the bend radius to prevent unnecessary stress. And the bend relief can be rectangular, round-ended, or a custom shape, depending on your part design.

There are also some basic rules for sizing these reliefs too:

For laser-cut parts:

For router-cut parts (used in bent aluminum with machined features like pockets or counterbores):

Conclusion

Bend reliefs play a crucial role in preventing issues during bending. Not adding these reliefs can lead to cracking, tearing, or warping of the material, compromising the integrity of your design.


Accelerate Your Project Velocity

At ProtoSpace Mfg, we help innovators bring their custom sheet metal, machined parts and enclosures to life in just 2-3 days. With our revolutionary High Velocity Mass Customization (HVMC) model, we allow you to eliminate any latencies with getting custom parts manufactured. This means you’ll accelerate your project velocity and keep your momentum going.

If you have a design ready, use our Instant Quoter tool to get a quote in seconds!

Contact one of our friendly and knowledgeable account managers to get started with us today.

Contact Us Today