The Ultimate Guide to Dimple Dies: Strength, Weight Savings, and Design Perks

November 12, 2024
Services

Dimple dies, also known as dimple forming, is our most recently added service in our growing list of sheet metal finishing service options. Not only do they offer incredible structural benefits, but they also save weight and add an aesthetic look to your parts. Whether you’re building race cars, aircraft components, or just want a unique finish on your part, dimple dies might be the perfect solution.

In this article, we’ll cover:

What dimple dies are and how they work
Applications and benefits of dimple forming
Design considerations and common mistakes to avoid
Alternatives and best practices for achieving similar results

This article is the written version of SendCutSend’s Cutting Corners episodes. Watch the video below subscribe on YouTube so you never miss a video.

Sheet Metal Dimple Forming: Video Guide

What Are Dimple Dies?

Dimple dies (or dimple forming) is a metal forming operation that creates flared holes in a part. This technique is used both for aesthetic and structural purposes, offering several advantages:

Added Rigidity: The flared edges of a dimple increase the stiffness of the material, similar to adding a bend.
Weight Savings: By removing material and simultaneously reinforcing it, dimple dies allow for thinner, lighter parts without compromising strength.
Anti-Slip Surfaces: The textured surface can also serve as a tread for safety applications.

Applications of Dimple Dies

Dimple dies are commonly seen in:

Race Cars: Known as “speed holes,” these reduce weight while maintaining structural integrity.
Aircraft: World War II-era planes often used this technique to add stiffness to thin panels.
Cosmetic Finishes: Adds character to parts, making them visually appealing.
Functional Surfaces: Footplates, stair treads, and RV steps benefit from the anti-slip properties.

Sheet Metal Design Considerations for Dimple Forming and Mistakes to Avoid

Dimple dies are a fantastic tool, but there are some critical guidelines to follow for optimal results:

Avoid Edges and Bends:
- Dimples introduce deformation, which can cause issues near edges or bends. Ensure there’s enough distance to prevent incomplete forming or stress concentration.
- Tip: Refer to SendCutSend’s dimple forming guidelines for minimum distances between features.
Account for Tooling Size:
- The die and punch used for dimpling are larger than the actual dimple. Be mindful of spacing to avoid collisions with other features or dimples.
- Instant DFM Check: When you upload your part to SendCutSend, their system flags potential issues like collisions.
Manage Stress and Bowing:
- Adding multiple dimples in a row can create bowing due to uneven stress. Counteract this by incorporating bends into your sheet metal design to straighten the material.
Material Limitations:
- Works best with formable materials like mild steel, stainless steel, and 6061 aluminum.
- Thickness is limited to .125 inches (3mm) for safety and effectiveness.

Alternatives to Dimple Dies

If dimple forming doesn’t fit your application, there are alternatives to consider:

Add Bends: Simple bends can achieve similar rigidity without removing material.
Bead Rolling: Adds stiffness through grooves but requires specialized equipment.
Thicker Material: Opt for a stronger or thicker material like 7075 aluminum for added strength, though it increases weight and cost.

Key Benefits of Dimple Dies

Why should you consider dimple forming for your project?

Saves Weight: Achieve the same strength as a thicker material without the bulk.
Looks Awesome: Perfect for race cars, industrial designs, or even laptop stands.
Affordable: Economical to implement, especially with volume discounts from SendCutSend.
Functional: Anti-slip surfaces for safety-critical applications.

Dimple dies are a versatile and cost-effective way to enhance your parts. Whether you’re looking to save weight, add strength, or simply make your design stand out, this process offers a range of benefits. With tools like instant DFM checks and clear guidelines, SendCutSend makes it easy to incorporate dimples into your design.