To complete this section and all following sections, you will require a copy of the SolidWorks software program, along with basic working knowledge. This includes how to carry out operations such as starting new parts, creating and editing sketches and features, and using common tools. For readers who are completely new to SolidWorks, it is advisable to gain a firm foundation of solid modeling first, before undertaking the Sheet Metal module covered in this book.

During the course of the book, if a certain tutorial or tool is causing problems, then try double-checking all of the previous steps, or even try closing the part and starting again from the beginning.

Error messages in SolidWorks can be quite descriptive and often tell the user exactly what the issue is. So, if presented with an error, then try to avoid the temptation to click OK without reading it properly, and attempt to carry out the action suggested in the message.

If the problems persist, then feel free to contact me online via Twitter at www.twitter.com/johnoellison.

SolidWorks versions

The examples and demonstrations in this book were made using SolidWorks 2021. Other versions of SolidWorks may have very minor differences in things such as the interface and how certain options are labeled, but in general, the workflow should be very similar. If you do get stuck on any of these differences, then please contact me using the details previously provided.

Units of measurement

Throughout this book, millimeters (mm) are used as the unit of measurement, but this can be adjusted according to the reader's preference by setting the model's units to inches ("), for example, and then typing the millimeter numerical value followed by mm into the Smart Dimension tool when adding dimensions. This will automatically convert the millimeter values into inches (or your selected unit type).

Terminology

Throughout this book, "sheet metal" (lowercase) refers to the general industry and manufacturing methods used in the real world, whereas "Sheet Metal" (capitalized) refers specifically to the SolidWorks Sheet Metal module.

The term "part" refers to a real-life component or item, whereas part (italicized) refers specifically to a SolidWorks part document.

Sheet metal parts are those that are—as the name suggests—created from flat sheets of metal. Numerous different manufacturing techniques such as bending, cutting, and forming allow these simple flat sheets to be transformed into complex 3D parts. The popularity of sheet metal has exploded in modern times because it allows designers and engineers to take a widely available material type—the flat sheets—and use relatively low-cost tools and processes to create complex products, at an industrial scale.

The chances are that a quick look around your home, garage, or workplace will reveal dozens of items that were created using sheet metal techniques. These can range from very simple items such as right-angle brackets to more complex products such as furniture, all the way up to detailed designs such as computer or electronics enclosures. Sheet metal is also used to create very complex items such as aircraft parts or car bodywork, although the most advanced formed parts are beyond the scope of SolidWorks Sheet Metal.

Figure 1.1: Examples of sheet metal parts

The beauty of the SolidWorks Sheet Metal module is that it allows users to create these 3D shapes, then flatten them down to sheets, and export them as two-dimensional (2D) designs that can be used for manufacturing.

Another great aspect of SolidWorks Sheet Metal is that, despite the name, it doesn't have to be used for purely metal parts. Sheet Metal can be used to create any kind of flattened 3D part, regardless of the real-life material. Try to think beyond the "metal" title, and a wide range of other uses can be unlocked. For example, Sheet Metal can be used to create cardboard packaging. This can be modeled in 3D before being virtually unfolded to be printed, cut out with a die-cutter, and then turned into 3D boxes. Sheet Metal can also even be used to create items as diverse as paper origami artwork.

Figure 1.2: Sheet Metal isn't just for metal but any material, such as this cardboard packaging

Sheet Metal is a diverse set of manufacturing methods that will take your modeling and design to the next level. In summary:

• Sheet metal uses flat sheets to create 2D or 3D parts.
• Techniques include cutting, bending, and forming.
• SolidWorks Sheet Metal parts don't have to be metal!

In the next section, we'll look at how we can actually start making Sheet Metal parts in SolidWorks by creating a Base Flange that will be the foundation feature of these parts.