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Sheet Metal and Plastic Bending Calculator

Use SendCutSend’s bending calculator to input your desired material and the units of measurement for your design to get the calculated bend allowance and bend deduction for your part before sending it to our lasers. The calculator also allows you to input flanges.
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Using the Bend Calculator

Step 1:

Select material type, thickness, and desired units

Step 2:

Enter your base length

This represents the overall outside desired dimension of the base, center, or largest section of the part. If this was a U-channel, this would be the outside dimension after bending of the center section.

Step 3:

Enter your flange dimensions

These are also entered at the desired outside dimension after bending. You can adjust the flanges to be on either side of the base by selecting the left or right position.

Formed flange lengths should always be measured from the apex of the bend.

Acute Flange Apex Dimensions
Acute Flange Apex Dimensions
Obtuse Flange Apex Dimensions
Obtuse Flange Apex Dimensions

This will result in the Sketch view (see below) showing the location the bend lines need to be placed in the flat pattern with the bend deduction taken into consideration.

Step 4:

Select your view

In the Results section, the default option is a flat view of the part you are gathering data for. You can select the 3D view to ensure your bends are as you expected.

Step 5:

Adjust your design

You can then adjust your design to match the overall outside dimension (17.765”) and add the bend lines (3.903”) from the edge of the part. Once this is bent, it will have the desired outside flanges (4” outside dimension) and base (10” outside dimension). See Example 1 below.

If you’re utilizing 3D CAD software, draw the part with the flanges in place using the sheet metal function in whatever CAD software you are using. Once you have the flanges in place, edit the bend radius to match the advanced details found at the bottom of the bending calculator. Once the radius is updated, adjust the K-factor or Bend deduction value to match that in the advanced details. To verify the part is correct you can flatten then measure the overall length, and bend line locations in reference to the bend calculator layout.

Keep in mind if you need a specific inside dimension you will need to add some clearance (at least 0.030”) and adjust based on the material thickness. For example, this part will have an inside dimension of about 9.762”

Example 1
Example 1
Example 2
Example 2

For this example, using 0.119” Mild Steel and bending at 90°, we will have a bend deduction value of 0.194” for each bend which is where we get the total length of 17.612. You can find the bend deduction value at the bottom of this page in the “Advanced Details.” If you want to learn more about calculating bend deduction, check out our Guide to Calculating Bend Allowance and Bend Deduction. See Example 2 above.

Bending specifications per material

MaterialThicknessK FactorBend Deduction @ 90°Effective Bend Radius @ 90°Die WidthMin Formed Flange Length @ 90° 
1075 Blue Temper Steel.015″N/AN/AN/AN/AN/A
 
2024 T3 Aluminum.025″N/AN/AN/AN/AN/A
 
4130 Chromoly.050″.38.0945″.050″.472″.302″
.063″.41.1065″.050″.472″.308″
.125″.43.2050″.090″.984″.723″
.190″.37.3240″.125″.984″.782″
.250″.36.4335″.170″1.575″1.367″
 
5052 Aluminum.040″.45.062″.024″.472″.286″
.063″.42.096″.035″.472″.303″
.080″.43.115″.050″.472″.313″
.090″.37.142″.032″.472″.326″
.100″.40.191″.125″.630.463″
.125″.44.216″.125″.630″.476″
.187″.43.356″.250″.984″.798″
.250″.42.442″.250″1.575″1.371″
.375″N/AN/AN/AN/AN/A
.500″N/AN/AN/AN/AN/A
 
6061 Aluminum.040″N/AN/AN/AN/AN/A
.063″N/AN/AN/AN/AN/A
.080″N/AN/AN/AN/AN/A
.125″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
.375″N/AN/AN/AN/AN/A
.500″N/AN/AN/AN/AN/A
 
7075 Aluminum.125″N/AN/AN/AN/AN/A
.190″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
 
ABS.125N/AN/AN/AN/AN/A
.187″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
 
Acrylic.118″
(all colors)		N/AN/AN/AN/AN/A
.177″
(clear)		N/AN/AN/AN/AN/A
 
ACM.118″
(black, white, brushed)		N/AN/AN/AN/AN/A
.236″
(black, white)		N/AN/AN/AN/AN/A
 
AR400.250″N/AN/AN/AN/AN/A
 
AR500.119″N/AN/AN/AN/AN/A
.187″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
.375″N/AN/AN/AN/AN/A
.500″N/AN/AN/AN/AN/A
 
Baltic Birch Plywood.125″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
.354″N/AN/AN/AN/AN/A
.472″N/AN/AN/AN/AN/A
 
Brass.040″.38.074″.040″.472″.292″
.063″.38.105″.040″.472″.308″
.125″.38.205″.060″.630″.471″
.187″.38.324″.095″.984″.782″
.250″.38.424″.130″1.575″1.362″
 
Carbon Fiber.040″N/AN/AN/AN/AN/A
.063″N/AN/AN/AN/AN/A
.079″N/AN/AN/AN/AN/A
.118″N/AN/AN/AN/AN/A
 
Chipboard.063″N/AN/AN/AN/AN/A
 
Copper.040″.34.081″.052″.472N/A
.063″.36.099″.024″.472″N/A
.125.34.205″.050″.630″N/A
.187″.36.320″.118″.984″N/A
.250″.33.430″.140″1.575″N/A
 
Cork (Gasket Grade).063″N/AN/AN/AN/AN/A
.125″N/AN/AN/AN/AN/A
 
Delrin.125″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
 
G10/FR-4.063″N/AN/AN/AN/AN/A
.125″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
.375″N/AN/AN/AN/AN/A
 
G30 Steel.036″.38.0730″.045″.472″.298″
.048″.38.0860″.045″.472″.298″
.059″.36.1120″.063″.472″.311″
 
Hardboard.125″N/AN/AN/AN/AN/A
 
HDPE.250″N/AN/AN/AN/AN/A
.375″N/AN/AN/AN/AN/A
.500″N/AN/AN/AN/AN/A
 
LE Phenolic Linen.125″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
.375″N/AN/AN/AN/AN/A
 
MDF.125″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
.375″N/AN/AN/AN/AN/A
.472″N/AN/AN/AN/AN/A
 
Mild Steel.030″.38.0610″.045″.472″.286″
.048″.38.0860″.045″.472″.298″
.059″.36.1120″.063″.472″.311″
.074″.40.1290″.063″.472″.320″
.104″.34.1815″.063″.630″.459″
.119″.38.1955″.063″.630″.466″
.135″.32.2440″.100″.984″.742″
.187″.36.3225″.125″.984″.781″
.250.36.4215″.150″1.575″1.361″
.375″N/AN/AN/AN/AN/A
.500″N/AN/AN/AN/AN/A
 
Polycarbonate.118″.330.1950″0.040″0.472″0.368″
.177″.330.2960″0.085″0.984″0.798″
.220″.330.3670″0.225″1.575″1.389″
 
304 Stainless Steel.030″.36.0785″.080″.472″.294″
.048″.36.1045″.080″.472″.307″
.060″.34.1185″.070″.472″.314″
.074″.36.1370″.075″.472″.324″
.100″.36.2230″.187″.984″.732″
.125″.38.2400″.150″.984″.740″
.187″.36.3285″.130″.984″.784″
.250″.36.4620″.225″1.575″1.381″
.375″N/AN/AN/AN/AN/A
.500″N/AN/AN/AN/AN/A
 
316 Stainless Steel.060″.34.1185″.070″.472″.314″
.125″.38.2400″.150″.984″.740″
.187″.36.3285″.130″.984″.784″
.250″.36.4620″.225″1.575″1.381″
 
Titanium Grade 2.040″.38.0790″.045″.472″.294″
 
Titanium Grade 5.040″N/AN/AN/AN/AN/A
.060″N/AN/AN/AN/AN/A
.125″N/AN/AN/AN/AN/A
.187″N/AN/AN/AN/AN/A
.250″N/AN/AN/AN/AN/A
 
UHMW.375″N/AN/AN/AN/AN/A
.500″N/AN/AN/AN/AN/A

Additional Charts and Guidelines

Min/Max Part Sizes

Processing Min/Max Part Sizes

Part Density Guidelines

Material Selection Guide

Nesting Guidelines

Bending Deformation Guidelines

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Flush stud, M8 x 1.25, .472" Zinc plus Clear Chromate

SKUFH-M8-12
Thread SizeM8 x 1.25
Hole size in sheet (+0.003/-.0.000).315″
Minimum sheet thickness0.94″
Maximum sheet thickness.347″
Fastener materialSteel
Minimum distance hole C/L to edge0.378″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole..535″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Length.472″
Aluminum material ranges (5052, 6061, 7075)0.100″-0.250″
Steel material ranges (CRS, HRPO, HR)0.104″-0.250″

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Flush Standoff, 4-40, .250" Zinc plus Clear Chromate

SKUSO-440-8
Thread Size4-40 x .250″
Hole size in sheet (+0.003/-.0.000).168″
Minimum sheet thickness0.040″
Maximum sheet thickness.125″
Fastener materialSteel
Minimum distance hole C/L to edge0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole..314″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Length.250″
Aluminum material ranges (5052, 6061, 7075)0.040″-0.125″
Steel material ranges (CRS, HRPO, HR)0.048″-0.119″