How to Do a Lofted Bend in SOLIDWORKS

A lofted bend in SOLIDWORKS creates a sheet metal transition between two sketch profiles. It is commonly used for duct transitions, hoppers, reducers, adapters, and formed sheet metal parts where one shape changes into another.

Start with two clean profiles

Create two sketches on separate planes. The profiles should represent the start and end shapes of the sheet metal transition. Keep the sketches simple, closed, and dimensioned. Lofted bends are easier to control when the sketches have matching intent and clean corners.

If the transition changes from round to rectangular, make sure the profiles are positioned around the correct centerline or reference geometry. Misaligned profiles can twist the bend or create an awkward flat pattern.

Try to keep similar points aligned between the two sketches. For example, place the top, bottom, left, and right references consistently so the transition develops in a predictable way.

Create the lofted bend

1. Start a sheet metal part.
2. Create the first profile sketch.
3. Create a second plane and sketch the second profile.
4. Open the Lofted Bend command.
5. Select the two profiles in the correct order.
6. Set thickness, bend options, and facet settings.
7. Confirm the preview and create the feature.

Choose formed or bent behavior

SOLIDWORKS can create lofted bends with different behavior depending on the selected options. A formed transition may look smoother, while a bent or faceted transition may be better for manufacturing and flat pattern output.

Choose the option that matches how the part will be made. If the shop needs a flat pattern made from bend segments, the faceted result may be more practical than a visually smooth surface.

Check thickness and bend settings

Set sheet thickness, bend radius, bend allowance, or K-factor according to the material and manufacturing process. These values affect the flat pattern and the final formed size.

If the part will be fabricated, avoid guessing these settings. Use shop standards or confirmed sheet metal data so the model matches the intended bend process.

Review the flat pattern

After creating the lofted bend, flatten the part and inspect the flat pattern. Check whether bend lines, seam location, and developed shape make sense. A lofted bend that looks acceptable in 3D may still create a poor or unexpected flat pattern.

Pay attention to the seam or open edge. Its location can affect welding, forming, and appearance, so place it where it is practical for manufacturing.

Also check the bend-line spacing and any small sliver faces in the flattened result. Very narrow regions may be difficult to cut or form cleanly, even if SOLIDWORKS can generate the flat pattern.

Troubleshooting

If the lofted bend fails, simplify the profiles and check that both sketches are closed. If the transition twists, add reference points or adjust sketch alignment. If the flat pattern looks wrong, review thickness, bend settings, and the selected lofted bend type.

For production parts, confirm the flat pattern with the fabricator before cutting material. Lofted bends can be sensitive to process assumptions, especially for transitions with tight corners or large shape changes.

Use a drawing or exported flat pattern that clearly shows bend lines, material, thickness, and revision. That keeps the SOLIDWORKS model connected to the way the part will actually be made.

If the lofted bend is part of a larger assembly, test the formed part in context before release. Clearance around flanges, weld seams, and neighboring components can change once the transition is installed.