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.