How to Convert to Sheet Metal in SOLIDWORKS

Convert to Sheet Metal in SOLIDWORKS turns suitable solid geometry into a sheet metal part with bends, thickness, reliefs, and a flat pattern. It is useful when a part was modeled as a solid first but needs to be manufactured from sheet metal.

Start with suitable geometry

The solid body should have consistent wall thickness and bend-like corners. Convert to Sheet Metal works best when the model already resembles a formed sheet metal part.

If the model has inconsistent thickness, complex blends, or features that cannot unfold, simplify it before converting.

Look for corners that should become bends and edges that should become rips. Planning those areas before starting the command makes the conversion more predictable.

Select the fixed face

The fixed face controls how the part unfolds. Choose a stable face that makes sense for the flat pattern and manufacturing process. A poor fixed-face choice can make the flat pattern harder to interpret.

After selecting the fixed face, review the preview and confirm the part unfolds in the intended direction.

The fixed face is often the largest or most stable face, but that is not a rule. Choose the face that best supports manufacturing, dimensioning, and flat-pattern orientation.

Define bends and edges

Select the edges that should become bends and set the sheet metal parameters such as thickness, bend radius, and relief. These values affect the folded model and the flat pattern.

Use real shop standards when possible. Bend radius, K-factor, and relief settings should match how the part will actually be made.

If the part will be sent to an outside supplier, confirm their preferred bend allowance or K-factor method. Different shops can use different standards for the same material thickness.

Create and inspect the flat pattern

After conversion, flatten the part and inspect the flat pattern. Check bend lines, relief cuts, outside shape, and any holes or features near bends.

If the flat pattern fails, review thickness, bend selections, corner conditions, and geometry that may not be unfoldable.

Check holes and cutouts near bends carefully. Features too close to bend lines can distort during forming or require special manufacturing attention.

Clean up the sheet metal model

Once the part converts successfully, check the feature tree and rename important features. Add or adjust sheet metal features such as edge flanges, cuts, or reliefs if the converted model needs cleanup.

Do not assume the converted part is ready for fabrication just because it flattens. Verify dimensions, bend notes, material, and export settings.

Also check whether the converted feature tree is easy to edit. Sometimes rebuilding the part with native sheet metal features is cleaner than keeping a fragile converted solid.

Troubleshooting

If Convert to Sheet Metal fails, check for non-uniform wall thickness, missing rip edges, tight corners, or geometry that cannot unfold. Try converting a simpler body first to isolate the problem.

Before sending a flat pattern to manufacturing, confirm material thickness, bend radius, bend allowance, grain direction if needed, and revision. Sheet metal conversion is only useful when the flat pattern matches the real process.

For production parts, review the converted model in both folded and flat states so the design is clear from every manufacturing viewpoint.

If the flat pattern will be exported as DXF, open the exported file and measure a known dimension. This catches scale or unit problems before the file reaches a cutting machine or supplier.

For assemblies, check the converted sheet metal part in context after flattening and refolding. Bend reliefs, flange changes, and thickness corrections can affect neighboring parts.