FreeCAD Sheet Metal Tutorial 2025: Model 0126 – Bend, Flange & Unfold a Professional Enclosure [Step-by-Step Video Guide]
Struggling with sheet metal design in FreeCAD? If you're coming from SolidWorks and missing easy bends or flanges, this FreeCAD sheet metal tutorial 2025 for Model 0126 will change that. We'll create a simple yet professional enclosure (like a control box panel) using the SheetMetal workbench – from sketch to unfolded DXF export. Perfect for beginners to advanced users in mechanical engineering or 3D printing prep.
No paid software needed – FreeCAD 1.0 is free and parametric. This guide takes ~15 minutes, with timestamps from my YouTube video. For more FreeCAD basics, check my Loft Pipe Tutorial or Mobile Holder Model.
Why FreeCAD for Sheet Metal? (Vs. SolidWorks Quick Comparison)
FreeCAD's SheetMetal add-on (install via Addon Manager) mimics SolidWorks but is open-source. Key differences:
| Feature | FreeCAD | SolidWorks |
|---|---|---|
| Bend Tool | Parametric, auto-relief | Similar, but license cost |
| Unfold Export | DXF/STEP free | Pro version needed |
| Learning Curve | Steeper but tutorials abound | Intuitive for pros |
Pro tip: Install SheetMetal workbench first (Tools > Addon Manager > Search "SheetMetal"). Let's dive in!
Tools & Setup Needed (FreeCAD 1.0 Recommended)
- Workbench: SheetMetal (switch via dropdown).
- Key Tools: Sketcher (for base), Bend, Flange, Unfold, Extend.
- File: New document; units in mm.
- Download: FreeCAD from freecad.org (2025 version for best stability).
Step-by-Step Guide: Build Model 0126 (with Timestamps)
- 0:00 – Create Base Sketch (Rectangle Face)
Switch to Sketcher workbench. Draw a 200x150mm rectangle on XY plane. Close and exit sketch. Extrude to 2mm thickness (for 1.5mm sheet).
- 2:30 – Add First Flange (Side Wall)
Switch to SheetMetal. Select base edge, click Flange tool. Set length=100mm, angle=90°, thickness=2mm. Auto-relief: Round.
- 5:15 – Create Bend on Opposite Edge
Select adjacent edge, use Bend tool. Radius=5mm, angle=90°. Preview and apply – it auto-folds.
- 8:00 – Add Tabs & Reliefs
For corners: Use Extend tool on edges, then Bend. Add tear drop relief to avoid cracks (Settings > Relief Type).
- 10:45 – Finalize with Holes & Cutouts
Switch to Part Design. Add Pocket for mounting holes (Ø4mm). Validate sheet metal rules.
- 13:30 – Unfold & Export DXF
Click Unfold button. Export as DXF for laser cutting (File > Export > DXF). Re-fold to check.
Common Mistakes & Pro Tips for Sheet Metal in FreeCAD
- Mistake: Wrong relief type – use "Tear Drop" for sharp bends to prevent material overlap.
- Tip: Always validate (SheetMetal > Validate) before export – catches thickness errors.
- Advanced: Integrate with Path workbench for CNC simulation. For complex hems, chain multiple Flanges.
- Vs. SolidWorks: FreeCAD lacks auto-miter, but it's 100% free – save $1000s!
Done! Your Model 0126 enclosure is ready for 3D print or fab shop. Practice on variations (e.g., add lid). Questions? Contact me or comment below.
 |
| The drawing needed to complete the tutorial. |
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Tags: FreeCAD sheet metal tutorial, FreeCAD bend tool, FreeCAD flange 2025, FreeCAD vs SolidWorks sheet metal, FreeCAD Model 0126, FreeCAD unfold DXF, sheet metal modeling beginner, FreeCAD parametric design, 3D CAD tutorial
Updated: November 16, 2025
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