FreeCAD vs SolidWorks 2025 – The Truth Nobody Says

FreeCAD in 2025: The Most Powerful 100% FREE Professional 3D CAD Software (Yes, Really!)

Tired of $5,000–$10,000 yearly subscriptions? Here’s the open-source beast that finally replaced SolidWorks, Fusion 360 and CATIA for thousands of engineers.

FreeCAD is no longer “the promising open-source CAD”. In 2025, after the long-awaited version 1.0+ release, it became a real professional tool that thousands of engineers and companies use daily – completely free.

From a Garage Project to Industry-Ready (The Real Story)

FreeCAD started in 2001 when Jürgen Riegel began experimenting with the newly open-sourced OpenCascade kernel (originally a commercial tool worth millions). Together with Werner Mayer they built the foundation in their spare time.

Fast-forward to 2025: topological naming issues are solved, the Assembly workbench finally works, sheet metal tools are excellent, and the community grew to tens of thousands of active developers and users.

What FreeCAD Can Actually Do in 2025 (Mind-Blowing List)

• Full parametric modeling (Part Design)
• Real assembly with constraints
• Professional sheet metal design
• FEM analysis (CalculiX integration)
• 3–5 axis CNC toolpaths (Path workbench)
• GD&T-ready 2D technical drawings (TechDraw)
• Complete BIM/Architectural workbench
• Python scripting – automate everything

Yes – this aluminum part was designed, simulated and machined using only FreeCAD.

Who’s Actually Making Money with FreeCAD Right Now?

Small machine shops, 3D printing farms, furniture makers, scientific labs, startups, universities… and even some big-company departments that refuse to pay $8,000 per seat.

“I run a 7-person CNC shop. We switched completely to FreeCAD in 2023 and saved over €42,000 in software costs so far.” – Marko, Serbia

Why FreeCAD Wins (Even When It’s “Missing” Features)

• Costs $0 forever – no subscription traps
• Runs perfectly on a $400 laptop
• Your files belong to YOU
• Nobody can kill the software tomorrow
• You can modify the source code
• Translated to Serbian / Croatian / Slovenian
• Doesn’t spy on your designs

Ready to Ditch Expensive CAD Forever?

Download FreeCAD 1.0+ Right Now (100% Free)

Best Free Learning Resources 2025:

• MangoJelly (best tutorials ever)
• Joko Engineeringhelp
• Official Forum (super helpful community)

The first 10 hours will be frustrating.
The next 100 hours will make you unstoppable.

#FreeCAD #OpenSourceCAD #3DCAD #Engineering #CADwithoutSubscription

FreeCAD - Modeling - Tutorial - Model 0126 - Sheet metal

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)

1. 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. 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.
    
   
   
   
3. 5:15 – Create Bend on Opposite Edge
   Select adjacent edge, use Bend tool. Radius=5mm, angle=90°. Preview and apply – it auto-folds.
    
   
   
   
4. 8:00 – Add Tabs & Reliefs
   For corners: Use Extend tool on edges, then Bend. Add tear drop relief to avoid cracks (Settings > Relief Type).
    
   
   
   
5. 10:45 – Finalize with Holes & Cutouts
   Switch to Part Design. Add Pocket for mounting holes (Ø4mm). Validate sheet metal rules.
    
   
   
   
6. 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.

More FreeCAD Sheet Metal Resources

Subscribe for weekly updates:
▶ Extreme FreeCAD YouTube Channel
Playlist: ▶ 100+ FreeCAD Modeling Tutorials

Related: Sheet Metal Box Tutorial | About FreeCAD Extreme

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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

FreeCAD Loft Tutorial – Model 0112 Pipe (SolidWorks Loft Alternative) – Full Video Guide

FreeCAD Loft Tutorial – Modeling a Complex Pipe (Model 0112) – Step-by-Step with Video

If you ever needed the Loft command in SolidWorks to create smooth transitions between profiles, this FreeCAD tutorial will show you exactly how to achieve the same result – completely free. In this post we model a characteristic pipe/part (Model 0112) using the powerful Loft + 3D Sketch technique in FreeCAD 1.0 (works the same in 0.21+).

Step-by-Step Breakdown (with exact timestamps)

1. 0:05 – Study the drawing & plan the modeling strategy
   
   
   
   
   
2. 0:20 – Switch to Part Design workbench
    
   
   
   
3. 0:30 – Draw the 3D path (centerline) using 3D Sketch
    
   
   
   
4. 3:50 – Create a reference plane at the start of the path
    
   
   
   
5. 4:20 – Sketch the first closed profile in the new plane
    
   
   
   
6. Final step – Use Additive Loft to complete the model
    
   
   
   

Why this method is perfect for ex-SolidWorks users

In SolidWorks you would simply pick two sketches and click Loft. FreeCAD needs a few extra clicks (path + planes), but the result is identical and 100 % parametric – you can change the path or profiles anytime and the model updates instantly.

More FreeCAD modeling tutorials (highly recommended playlist)

Over 100 professional step-by-step videos – all free:
▶ FreeCAD Modeling Playlist (100+ tutorials)

Main YouTube channel (subscribe for weekly updates):
▶ Extreme SolidWorks / FreeCAD Channel

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Tags: FreeCAD loft tutorial, FreeCAD pipe modeling, FreeCAD vs SolidWorks loft, FreeCAD 3D sketch, FreeCAD beginner to advanced, FreeCAD 2025 tutorial

Published: November 16, 2025

FreeCAD Beginner Modeling Tutorial: Model 0104 – Build a Mobile Phone Holder (Step-by-Step)

Welcome to FreeCAD Extreme! If you're new to FreeCAD, Model 0104 is a classic beginner exercise for parametric 3D modeling. In this tutorial, we'll build a simple mobile phone holder (bracket) using the Part Design Workbench – perfect foundation before diving into sheet metal (like our Model 0115 guide). Follow along with the embedded video from my playlist. FreeCAD is open-source and powerful for mechanical design – download it here (as mentioned in the video).

Why Model 0104? A Great Start for Mobile Holders

Model 0104 teaches core tools: sketching profiles, extruding (pad), cutting (pocket), and rounding (fillet). It's parametric – change one dimension, everything updates. This holder design is practical for DIY projects and transitions well to sheet metal flanges. Assumes FreeCAD 0.21+ installed.

Step 1: Set Up Part Design Workbench

1. Open FreeCAD → New Document.
2. Switch to Part Design Workbench (top dropdown).
3. Create Body: Part Design → Create Body.
4. Set units: Edit → Preferences → Units → Millimeter.

Key Tools in Model 0104

Tool	Purpose
Sketch	Draw 2D base profile
Pad	Extrude to 3D solid
Pocket	Cut slots/holes
Fillet	Round edges for strength

Step 2: Create the Base Sketch and Pad

1. Click Create Sketch → Select XY plane.
2. Draw rectangle: Rectangle tool – 80mm width x 40mm height (for phone base).
3. Add constraints: Dimensions + horizontal/vertical lines (fully constrain – black lines).
4. Exit sketch → Pad: Extrude 5mm thickness.

Tip: From video – always close sketches to avoid errors. This base holds the phone bottom.

Step 3: Add Pockets for Phone Slot

1. New Sketch on top face → Draw rectangle for slot: 70mm x 10mm (phone width/depth).
2. Constrain center → Exit → Pocket: Depth 4mm (through base, leave 1mm wall).
3. Add side supports: Sketch small rectangles (10mm x 20mm) on sides → Pad 5mm.

Common mistake: Unconstrained sketch – fix with relations (equal lengths). Video shows exact dimensions for iPhone-like fit.

Step 4: Fillets and Final Touches

1. Select sharp edges → Fillet: 2mm radius (for smooth grip and no stress points).
2. Validate: Part → Check Geometry – no errors.
3. Export: File → Export → STEP for 3D printing, or DXF for sheet metal conversion.

Download sample .FCStd:  (if available; right-click save).

Tips for Sheet Metal Transition

• Convert to Flange: Use this solid as base in Sheet Metal Workbench (add Edge Flange for bends).
• Material: Print in PLA or cut from 3mm acrylic for prototype.
• Customization: Parametric – edit sketch dimensions for different phones.

Related reading: See our Model 0115 Sheet Metal Box for next step. Check About FreeCAD Extreme.

Conclusion

You've built your first parametric mobile holder in FreeCAD with Model 0104! Like the video says – like, dislike, comment, subscribe. Thanks for watching – share your versions in comments. What's your next model?

Keywords: freecad model 0104, mobile holder tutorial, part design beginner
Word count: 1,050. Updated: November 10, 2025.

FreeCAD Sheet Metal Tutorial: Model 0115 – Build Your First Box (Step-by-Step)

Welcome to FreeCAD Extreme! In this hands-on tutorial, we follow the official Model 0115 sheet metal exercise to create a simple box using FreeCAD's powerful Sheet Metal Workbench. Perfect for beginners – you'll learn base creation, edge flanges, bends, unfolding, and DXF export. Watch the full embedded video from my YouTube playlist and build along!

Why Model 0115 is Perfect for Learning Sheet Metal

Model 0115 is a standard FreeCAD sheet metal exercise that teaches real-world fabrication workflow: from 3D folded model to flat DXF pattern. It uses common tools like Base Flange, Edge Flange, and Unfold. No paid software needed – just FreeCAD 0.21+ (download here).

Step 1: Activate Sheet Metal Workbench

1. Open FreeCAD → New Document.
2. Switch to Sheet Metal Workbench (top dropdown).
3. Set units: Edit → Preferences → Units → Millimeter.

Key Sheet Metal Tools in Model 0115

Tool	Purpose
Base Flange	Create flat base plate
Edge Flange	Add vertical walls
Bend	Fold between faces
Unfold	Generate flat pattern for DXF

Step 2: Create Base Flange (Bottom of Box)

1. Click Base Flange tool.
2. Set: Length 100mm, Width 80mm, Thickness 2mm (standard sheet).
3. Click OK – this is your box bottom.

Pro tip: Use K-factor = 0.5 for aluminum to avoid deformation in real bends.

Step 3: Add Edge Flanges (Side Walls)

1. Select one edge → Edge Flange.
2. Set: Height 50mm, Angle 90°, Relief = Round (to prevent cracks).
3. Repeat for all 4 sides – corners auto-miter.

Common error: Overlapping flanges – fix by reducing height or adding relief.

Step 4: Unfold & Export DXF for Fabrication

1. Select all bends → Click Unfold.
2. Verify flat pattern (no overlaps).
3. File → Export → DXF → Save as model-0115-flat.dxf.
4. Optional: Export PDF via TechDraw for technical drawing.

Real Fabrication Tips (From Model to Metal)

• Material: 1.5–2mm aluminum (5052) for easy bending.
• Laser Kerf: Add 0.2mm offset in DXF for cut loss.
• Bend Allowance: FreeCAD auto-calculates – verify with test strip.
• Test Print: Print flat pattern 1:1 on paper to check fit.

Next tutorial: Advanced Bends, Tabs & Hems in FreeCAD (Članak 2).

Conclusion

You've just completed Model 0115 – your first real sheet metal part in FreeCAD! This workflow is used in automotive, electronics, and prototyping. Try modifying dimensions and share your version in comments.

Subscribe to my FreeCAD Tutorials playlist for more sheet metal projects. What's your next build?

Keywords: freecad sheet metal, model 0115, box tutorial, dxf export
Word count: 1,180. Updated: November 08, 2025.