DIN 6935 Sheet Metal U-Bend & K-Factor Standard 1:1 DXF · SVG · PDF Default Spec: 120 × 75 × 45 mm (T=2mm)

Sheet Metal U-Channel & Flanged Mounting Bracket Flat Pattern Generator (K-Factor DXF)

1:1 CAD ENGINE READY

Sheet Metal U-Channel & Flanged Mounting Bracket Flat Pattern Generator (K-Factor DXF)

1CAD Style & Material SetupSheet

Select CAD Style / Model (36)Search & Filter

Material Stock Preset (Auto-Sets Caliper T & Kerf K)

Display Units

Reference Mode

2Dimensions (ID Mode)Millimeters (mm)

Center Channel Web Width (L)120 mm

Bracket Extrusion Depth (W)75 mm

Side Flange Leg Height (H)45 mm

Inside ID: 120×75×45mmOutside OD: 124×79×49mm

Thickness (T mm)

Laser Kerf (K mm)

3Brand Logo & 1:1 ExportZero Login

2D & 3D Brand Logo Mockup:

📤 Upload Logo

Print Artwork Bleed Guide:

Embed Spec Sheet & 50mm / 1" Scale Bars (Added on separate DIMENSIONS layer)

Pre-Flight Geometry Audit8/8 PASSED

PASS
Closed Outer Contours: 7 closed LWPOLYLINE cut loop(s) verified
PASS
Zero Duplicate Cut Paths: 128 unique segments (0 laser double-burns)
PASS
Flute & Kerf Tolerance Guard: T=2.00mm, K=0.000mm within structural limits
PASS
ISO Layer Color Separation: CUT (Red), CREASE (Blue), SCORE (Emerald), DIMENSIONS isolated
PASS
1:1 Physical Unit Header: Explicit mm/in SVG viewBox + DXF $INSUNITS=4 + 50mm PDF bar
PASS
Exact 2D Cut Bounding Parity: Cut Bounds 206.46×75mm === Blank Size
PASS
2D ↔ 3D Kinematic Model Sync: Archetype 'sheet_metal_u_bracket' synced (3 3D component(s))
PASS
True Vector Sheet Nesting Sync: 1:1 vector paths mapped to multi-up sheet grid

100%

CUT (0.73m) CREASE/SCORE (0.15m)● 7 Loops · Est. Cut: ~33s

1:1 Synced · Blank: 206.46 × 75 mm

2D 1:1 Unfolded Vector BlueprintBlank: 206.46 × 75 mm (8.13" × 2.95")

3D Interactive Fold & Orbit (Kraft Board)

80%

0%100%

Camera:

Yaw: -28°Pitch: 24°

⟳ Drag Anywhere to Rotate 3DL=120 × W=75 × H=45mm

U-CHANNEL WEB (120×75mm)

LEG (45)

Developed Flat Pattern

206.5 × 75.0 mm

90° Bend Allowance

4.46 mm

Mounting Holes (6×)

Ø10.0 mm

K-Factor Standard

K = 0.42 (DIN 6935)

Structural & Manufacturing Specification Summary

Quick Default Download: ↓ .DXF ↓ .SVG ↓ .PDF

Fabricating a structural sheet metal U-channel, servo bracket, or clevis mount requires subtracting two 90-degree Bend Deductions (BD) from the total flat blank width so the bent side legs finish at exact parallel spacing (L). Our parametric U-bracket unfolder applies DIN 6935 neutral-axis K-Factor math (K = 0.42), chamfers all four outer mounting corners for deburred safety, places 6 precision closed bolt holes across the web and side legs, and isolates the two press-brake bend lines on the BLUE CREASE layer.

CUT LAYER #EF4444 (ACI 1)

CREASE / BEND #2563EB (ACI 5)

SCALE HEADER $INSUNITS=4 (1:1 mm)

SIMULATION 2D + 3D + Nesting

Pre-Calibrated Industry Sizes (1)

Standard Product Presets Built on This Sheet Metal U-Channel Bracket Engine

120 × 80 × 50 mm (T=2mm)

14ga U-Channel Bracket (120×80×50)

120 mm Web Width × 80 mm Depth × 50 mm Side Flange Legs (Formed 90° U-Bracket)

Load Preset Spec →

Structural Geometry & Allowances

Mathematical Blank & Tolerance Formulas

Total Developed Flat Pattern Width (W_flat)

W_flat = L_web + 2 * H_leg - 2 * BD_90

Subtracts two 90-degree press-brake bend deductions from the sum of the center web (L) and both side flange legs (2 × H).

90-Degree Bend Allowance (BA_90)

BA_90 = (pi / 2) * (R_inside + 0.42 * T)

Arc length along the sheet metal neutral axis (K = 0.42) for each 90-degree press-brake bend.

Pre-Press & Production SOP

Step-by-Step Export & Assembly Guide

1 Enter Center Channel Web Width (L), Bracket Extrusion Depth (W), Side Flange Leg Height (H), and Sheet Metal Thickness (T).
2 Review the flat pattern showing the chamfered outer profile, 6 closed mounting bolt holes (RED CUT layer), and 2 parallel press-brake bend lines (BLUE CREASE layer).
3 Check the 3D Fold Preview to inspect the 90-degree U-channel bend geometry.
4 Export as 1:1 .DXF for fiber laser, plasma, or waterjet cutting, then form the two 90-degree bends on a press brake.

Board Caliper, Laser & Die-Cutting Reference

Material Thickness, Creasing Matrix & Laser Kerf Settings

Material / Sheet Stock	Caliper Thickness (T)	Recommended Tooling / Laser Setup	Allowance / Kerf Spec	Primary Use Case
14 Gauge / 2.0mm Mild Steel (A36 / CRS)	2.00 mm (0.075 in)	Fiber Laser / Plasma + 16mm V-Die Press Brake	K-Factor: 0.42 / Inside Bend R: 2.0mm	Structural beam brackets, actuator clevis mounts, industrial framing
3.0mm 5052-H32 Aluminum Plate	3.00 mm (0.125 in)	Fiber Laser / Waterjet + 24mm V-Die	K-Factor: 0.40 / Inside Bend R: 3.0mm	Robotics chassis brackets, solar panel mounts, marine hardware

Packaging & CNC Engineering FAQ

Frequently Asked Questions — Sheet Metal U-Channel Bracket

Why is the unfolded flat width slightly shorter than L + 2H?

When sheet metal is bent 90 degrees on a press brake, the outside of the bend stretches. Subtracting the Bend Deduction (BD) ensures your finished U-bracket measures exactly L across the web and H along both legs after bending.

Are the 6 mounting holes exported as closed circles on the CUT layer?

Yes! All 4 side-leg bolt holes and 2 center-web mounting holes are exported as closed LWPOLYLINE loops on the CUT layer so your laser/plasma CAM software cuts the interior holes first before cutting the outer perimeter.

Can I use this U-channel bracket for 5052 aluminum as well as steel?

Yes. 5052-H32 aluminum and mild steel have nearly identical air-bending K-factors (0.40 to 0.42). Never use 6061-T6 aluminum for tight 90-degree bends, as T6 temper cracks along the bend line—always specify 5052-H32 for bent sheet metal brackets.

How are the press-brake bend lines separated from cut lines?

The two vertical 90-degree bend lines are placed on the 'CREASE' layer (Blue) so your CNC laser or plasma cutter ignores them or etches them lightly as operator alignment marks.

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