2

FORGE

a rule. Choose the rule for your chosen material.
Rotate the workspace and create the next flange
for the next side. This one needs to be slightly
narrower so there’s room for the tabs. Adjust the
size using the edge type option, the symmetric
option allows you to
define the length from
the middle to one side.
Next, create another
flange from the vertical
edge of the shortened
size just created. A
size of 10 mm should
be sufficient to provide
enough area for the joint to be soldered. Repeat
these steps to create the other sides and tabs.
To provide more strength to the box and protect
the user from sharp edges, the top edges are
folded over. The 180° fold will need to be done in
two steps, a short 2 mm flange followed by a longer
10 mm flange. When folding the second side of the

box, you will need to use the symmetrical offset

option to give clearance for the first edge.

The last step is to use the Modify->Create Flat

Pattern to create an unfolded version with the fold

lines marked on them.

From the flat pattern

you can then make

a drawing and either

print out full-size or

add dimensions to

use when marking out

the metal. The ‘linear

dimension’ works well

for this as it allows you

to measure between lines that are not joined up.

Change the precision of the dimensions to round to

the nearest mm.

The lid of the box is formed in the same way as

the box. When designing this, scale the sketch so

that the list is just bigger than the box. Use the

measure option on the box to check the folded

There are a variety of machines to help you form

folds in sheet metal. The simplest is a press brake, a

V-shaped anvil with a solid ‘knife’ to press the metal

into the V. These can be used in a press or vice.

Large versions of the press brake use levers or

hydraulics to push down the knife.

A pan folder uses a hinged bar to raise up the edge

in a similar manner to how we did the job manually.

FOLDING MACHINES

To provide more strength to

the box and protect the user

from sharp edges, the top

edges are folded over.

”

”

Above

Tab is inside the other flange

YOU’LL NEED

0.5 mm sheet

steel (not zinc-

coated)

Handles

Silver solder

Flux

Pop rivets for

handles

Safety equipment

A scribe

Layout blue or

a wide-tipped

permanent

marker

Ruler and square

Hacksaw

File

Clamps

Emery cloth

Gas Torch

Left

The complete pattern ready to be

transposed onto metal

Left

You can render the

final model to make

sure it looks as you

expect