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Welding",{"type":213,"value":214,"toc":620},"minimark",[215,219,227,240,250,255,258,274,286,290,293,314,321,326,333,345,349,352,417,423,427,430,452,456,459,463,466,470,473,477,480,484,487,491,499,508,512,529,533,536,565,576,579,583,605],[216,217,218],"p",{},"A bent box comes off the press brake with its corners open. The flanges are formed, but the seams\nbetween them are loose edges, and the part flexes more than it looks like it should. Welding those\nseams closes the corners and turns the formed blank into one rigid piece. It is the finishing step\nbehind most sheet metal enclosures, trays, boxes, and brackets.",[216,220,221,222,226],{},"Fabworks welds single ",[223,224,225],"a",{"href":17},"bent sheet metal parts"," in aluminum, steel, and stainless\nsteel. You add the welds yourself on the 3D preview of your part while you quote, and the price updates with the rest of the\norder. This guide covers how to set up a part in CAD so it welds cleanly, which weld to pick for each\nseam, and what we can't weld.",[228,229],"iframe",{"width":230,"height":231,"src":232,"title":233,"loading":234,"referrerPolicy":235,"frameBorder":236,"allow":237,"allowFullScreen":238,"style":239},315,560,"https:\u002F\u002Fwww.youtube.com\u002Fembed\u002FQDbmZCfnkYk","Welding is live on Fabworks","lazy","strict-origin-when-cross-origin","0","accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share",true,"display: block; margin: 0 auto",[241,242,243],"warning",{},[216,244,245,249],{},[246,247,248],"strong",{},"Assembly welding is not supported yet. Coming soon."," Welding is available for single bent sheet\nmetal parts only, welded along the part's own seams. We can't weld two or more parts together yet,\nand tube welding will come with assembly welding.",[251,252,254],"h2",{"id":253},"when-to-weld-a-bent-part","When to weld a bent part",[216,256,257],{},"Bending gets you most of the way to a box. Welding is what you add when the open corners are a\nproblem:",[259,260,261,268],"ul",{},[262,263,264,267],"li",{},[246,265,266],{},"The part needs to be stiff."," Open corners let the flanges flex and spread. A weld ties\nadjacent flanges together, so the whole part carries load as one piece.",[262,269,270,273],{},[246,271,272],{},"The seams need to be closed."," Trays, drip pans, and enclosures that should keep out dust or\nhold liquid need the corners filled.",[216,275,276,277,280,281,285],{},"If the part only needs to hold its shape and the seams can stay open, bends alone are cheaper.\nFor parts that need to come apart later, ",[223,278,279],{"href":40},"hardware"," such as PEM nuts and studs\njoins sheet metal without heat. The ",[223,282,284],{"href":283},"\u002Fblog\u002Ffastening-guide","sheet metal joining guide"," compares\nthe other options.",[251,287,289],{"id":288},"materials-and-thickness","Materials and thickness",[216,291,292],{},"Welding is available on single bent sheet metal parts in:",[259,294,295,301,307],{},[262,296,297],{},[246,298,299],{},[223,300,134],{"href":135},[262,302,303],{},[246,304,305],{},[223,306,138],{"href":139},[262,308,309],{},[246,310,311],{},[223,312,313],{"href":143},"Stainless steel",[216,315,316,317,320],{},"The maximum material thickness for welding is ",[246,318,319],{},"0.250\"",".",[322,323,325],"h3",{"id":324},"can-you-weld-galvanized-steel","Can you weld galvanized steel?",[216,327,328,329,332],{},"Not at Fabworks. The zinc coating burns off at welding temperatures and leaves a contaminated weld.\nIf a part needs welds and corrosion protection, weld a steel part and add\n",[223,330,331],{"href":46},"powder coating",", or choose stainless steel.",[216,334,335,336,339,340,344],{},"Every welded part is a bent part first, so it has to meet the\n",[223,337,338],{"href":94},"bending guidelines"," before any welds are added. Check flange\nlengths, bend radii, and feature distance from the bend lines there. The\n",[223,341,343],{"href":342},"\u002Fblog\u002Fsheet-metal-design-guide","sheet metal design guide"," covers the rest of bent part design.",[251,346,348],{"id":347},"setting-up-welded-corners","Setting up welded corners",[216,350,351],{},"How the flanges meet at a corner decides how well the corner welds. Thin sheet burns through\neasily, so it needs one flange to back up the other. Thick sheet needs room for the weld to\npenetrate. Set up each welded corner in your model based on the material thickness, and leave a\ngap between the flanges:",[353,354,358,414],"div",{"className":355},[356,357],"mx-auto","max-w-3xl",[359,360,361,377],"table",{},[362,363,364],"thead",{},[365,366,367,371,374],"tr",{},[368,369,370],"th",{},"Material thickness",[368,372,373],{},"Corner setup",[368,375,376],{},"Gap between flanges",[378,379,380,392,403],"tbody",{},[365,381,382,386,389],{},[383,384,385],"td",{},"0.032\" to 0.063\"",[383,387,388],{},"Full overlap",[383,390,391],{},"0.010\" to 0.020\"",[365,393,394,397,400],{},[383,395,396],{},"0.074\" to 0.135\"",[383,398,399],{},"Half overlap",[383,401,402],{},"0.010\" to 0.030\"",[365,404,405,408,411],{},[383,406,407],{},"0.160\" to 0.250\"",[383,409,410],{},"Corner to corner",[383,412,413],{},"0.010\" to 0.050\"",[415,416],"weld-corner-setup",{},[418,419,420],"tip",{},[216,421,422],{},"Most CAD sheet metal tools set the overlap and gap in the corner settings of the sheet metal\nfeature. Set them per corner to match the table above, then check the corners in the flat pattern\nbefore exporting your STEP file.",[251,424,426],{"id":425},"full-vs-stitch-vs-tack-welds","Full vs. stitch vs. tack welds",[216,428,429],{},"Each seam on a part can be welded one of four ways: full, stitch, tack, or manual.",[353,431,434],{"className":432},[356,433],"max-w-xl",[435,436,446,447],"video",{"autoPlay":238,"loop":238,"muted":238,"playsInline":238,"poster":437,"width":438,"height":439,"className":440,"ariaLabel":445},"\u002Fblog\u002Fsheet-metal-welding-design-guide\u002Fweld-types-poster.webp",1168,1080,[441,442,443,444],"w-full","rounded-lg","border","border-neutral-200","In the weld configuration view, choosing Tack and clicking a seam to add a tack weld, choosing Stitch to add 1 inch welds with 1 inch gaps along a seam, and choosing Full to weld a corner. Back on the quote, the Welding row shows four welds and the price updates","\n  ",[448,449],"source",{"src":450,"type":451},"\u002Fblog\u002Fsheet-metal-welding-design-guide\u002Fweld-types.mp4","video\u002Fmp4",[322,453,455],{"id":454},"full","Full",[216,457,458],{},"A continuous weld along the entire seam. Use full welds when the corner needs to be sealed, when\nthe part carries real load through the seam, or when the corner will be ground smooth for a\nfinished look.",[322,460,462],{"id":461},"stitch","Stitch",[216,464,465],{},"Short welds with gaps between them. The default is 1\" welds with 1\" gaps, and both are\nadjustable. Stitch welds hold the corner together and stiffen the part while putting much less\nheat into it than a full weld. That makes them a good fit for long seams on thin sheet, where a\nfull weld can warp the flanges.",[322,467,469],{"id":468},"tack","Tack",[216,471,472],{},"Small spot welds that hold the seam together without running a bead along it. Tacks work for\ncorners that only need to stay closed, such as a cover or a light bracket, and they put the least\nheat into the part.",[322,474,476],{"id":475},"manual","Manual",[216,478,479],{},"Drag along a seam to place weld segments exactly where you want them. Use manual welds when only\npart of a seam should be welded, for example to stay clear of a hole or a hardware location near\nthe corner.",[251,481,483],{"id":482},"heat-and-distortion","Heat and distortion",[216,485,486],{},"Every weld puts heat into the part, and heat moves thin sheet. A long full weld on 0.040\" aluminum\npulls harder on the flanges than the same weld on 0.125\" steel. If a seam doesn't need to be sealed,\nstitch or tack welds keep the part flatter. Keep welds away from features with tight\ntolerances when you can, since the area around a weld is the part of the sheet most likely to move.",[251,488,490],{"id":489},"grinding-welds-smooth","Grinding welds smooth",[216,492,493,494,498],{},"Any weld can be ground after welding to smooth the bead. Grinding blends the weld into the\nsurrounding sheet, so a full-welded corner looks like one continuous surface. It is a common choice\nfor visible corners and for parts that will be\n",[223,495,497],{"href":496},"\u002Fblog\u002Fpowder-coating-guide","powder coated",", where a smooth corner gives a cleaner finish.",[500,501],"img",{"loading":234,"decoding":502,"src":503,"alt":504,"width":505,"height":506,"className":507},"async","\u002Fblog\u002Fsheet-metal-welding-design-guide\u002Fgrind-welds.gif","In the weld configuration, checking Ground on each weld turns the welded seams from pink to teal to mark them as ground smooth",900,709,[356,441,433,442,443,444],[251,509,511],{"id":510},"what-we-cant-weld","What we can't weld",[259,513,514,517,520,523,526],{},[262,515,516],{},"Assemblies of two or more parts (coming soon)",[262,518,519],{},"Tube parts (coming with assembly welding)",[262,521,522],{},"Galvanized steel",[262,524,525],{},"Flat sheet metal parts",[262,527,528],{},"Material thicker than 0.250\"",[251,530,532],{"id":531},"adding-welds-to-your-quote","Adding welds to your quote",[216,534,535],{},"Welds are set up in the quote, not in your CAD file. You don't need to model weld beads. Model the\ncorners with the right overlap and gap, and leave the seams open.",[537,538,539,546,556,562],"ol",{},[262,540,541,545],{},[223,542,544],{"href":543},"\u002F","Upload a STEP file"," of your bent part and choose a material.",[262,547,548,549,551,552,555],{},"Each bent part shows a ",[246,550,51],{}," row. Click ",[246,553,554],{},"Open"," to open the weld configuration.",[262,557,558,559,561],{},"Pick a weld type, then click a seam on the 3D preview to weld it. In ",[246,560,476],{},", hold and drag\nalong a seam to place a segment.",[262,563,564],{},"Toggle grinding on any weld from the list of welds. The price updates as you go.",[353,566,568],{"className":567},[356,433],[435,569,446,573],{"autoPlay":238,"loop":238,"muted":238,"playsInline":238,"poster":570,"width":438,"height":439,"className":571,"ariaLabel":572},"\u002Fblog\u002Fsheet-metal-welding-design-guide\u002Fadd-welds-poster.webp",[441,442,443,444],"Uploading a STEP file of a bent aluminum box, choosing a material, opening the Welding row, and clicking a corner to add a full weld. Back on the quote, the Welding row shows one weld and the price updates",[448,574],{"src":575,"type":451},"\u002Fblog\u002Fsheet-metal-welding-design-guide\u002Fadd-welds.mp4",[216,577,578],{},"The Welding row shows a count of the welds on the part. If the part isn't eligible, such as a\ngalvanized steel part or one thicker than 0.250\", the quote tells you why so you can change the\nmaterial before checkout.",[251,580,582],{"id":581},"welding-design-checklist","Welding design checklist",[259,584,585,590,593,596,599,602],{},[262,586,587,588,320],{},"The part is a single bent part and meets the ",[223,589,338],{"href":94},[262,591,592],{},"The material is aluminum, steel, or stainless steel, 0.250\" or thinner, and not galvanized.",[262,594,595],{},"Each welded corner uses the right setup for its thickness: full overlap, half overlap, or corner\nto corner.",[262,597,598],{},"Every welded corner has a gap between the flanges within the range for its thickness.",[262,600,601],{},"Seams that don't need to be sealed use stitch or tack welds to limit heat and distortion.",[262,603,604],{},"Visible or powder coated corners are ground smooth.",[216,606,607,608,611,612,615,616,619],{},"For the full reference, see the ",[223,609,610],{"href":120},"welding guidelines",".\n",[246,613,614],{},"Not sure if your part can be welded?"," ",[223,617,618],{"href":543},"Upload your STEP file"," and open the Welding row on the\nquote.",{"title":621,"searchDepth":622,"depth":622,"links":623},"",2,[624,625,629,630,636,637,638,639,640],{"id":253,"depth":622,"text":254},{"id":288,"depth":622,"text":289,"children":626},[627],{"id":324,"depth":628,"text":325},3,{"id":347,"depth":622,"text":348},{"id":425,"depth":622,"text":426,"children":631},[632,633,634,635],{"id":454,"depth":628,"text":455},{"id":461,"depth":628,"text":462},{"id":468,"depth":628,"text":469},{"id":475,"depth":628,"text":476},{"id":482,"depth":622,"text":483},{"id":489,"depth":622,"text":490},{"id":510,"depth":622,"text":511},{"id":531,"depth":622,"text":532},{"id":581,"depth":622,"text":582},[642,643],"Design","Post Processing","2026-09-29","How to design bent sheet metal parts for welding. Covers supported materials and thicknesses, how to set up welded corners, choosing full, stitch, tack, or manual welds, and adding welds to your quote.","md","\u002Fblog\u002Fsheet-metal-welding-design-guide\u002Fthumbnail.webp",{},"\u002Fblog\u002Fsheet-metal-welding-design-guide",{"title":211,"description":645},"Design bent sheet metal parts for welding. Corner setups by thickness, weld gaps, full vs stitch vs tack welds, and how to add welds to a Fabworks quote.","Sheet Metal Welding Design Guide for Bent Parts",{"loc":649,"images":654},[655],{"loc":503},"blog\u002Fsheet-metal-welding-design-guide",{"name":233,"description":658,"embed_url":232,"thumbnail_url":659,"upload_date":660,"duration":661},"Fabworks now welds single bent sheet metal parts in aluminum, steel, and stainless steel. Add full, stitch, tack, or manual welds right on the 3D preview of your part.","https:\u002F\u002Fi.ytimg.com\u002Fvi\u002FQDbmZCfnkYk\u002Fmaxresdefault.jpg","2026-09-30T07:56:18-07:00","PT22S","3sOXk0inCGiSsp3FCLA_JOcGBNRwJYo3P5G0PO-7yeE",[664,669],{"title":665,"path":666,"stem":667,"description":668,"children":-1},"Press Brake Simulation: Watch Your Part Bend Before You Order","\u002Fblog\u002Fpress-brake-simulation","blog\u002Fpress-brake-simulation","Every bent part on a Fabworks quote now gets a press brake simulation. See each bend play out on our tooling, find collisions before you order, and learn what to change when no bend order works.",{"title":670,"path":671,"stem":672,"description":673,"children":-1},"Use AI to Check Your Sheet Metal Parts for Manufacturability","\u002Fblog\u002Fai-dfm-check-mcp","blog\u002Fai-dfm-check-mcp","Connect an AI agent to the Fabworks MCP server and have it check your STEP files for manufacturability, explain every issue, and re-check your fixes before you order.",1791179954437]