FreeCAD SheetMetal Workbench 2026: Beginner to Pro Tutorial & Unfold Guide

FreeCAD Sheet Metal 2026: The Ultimate Visual Tutorial & Guide

Updated March 2026 | FreeCAD Extreme Blog

Parametric sheet metal box – 3D model and flat pattern (unfolded) in FreeCAD 1.0+

In 2026, FreeCAD's SheetMetal workbench has become one of the best free tools for sheet metal design. With FreeCAD 1.0+ and latest SheetMetal updates (v0.7.65+), you can create flanges, bends, reliefs, unfold to DXF for laser/CNC, and export professional parts – all without paying.

What Makes SheetMetal Workbench So Good in 2026?

It handles constant-thickness parts perfectly: base walls, automatic bend allowances, corner reliefs, hems, and clean unfolds with bend lines.

SheetMetal workbench in action – creating a basic folded bracket

Quick Install Guide (2026 Steps)

1. Open latest FreeCAD (1.0 or 1.0.2+ recommended)
2. Tools → Addon Manager
3. Search "SheetMetal" → Install (by shaise)
4. Restart FreeCAD → Select "Sheet Metal" workbench

Pro Tip: Check for updates in Addon Manager regularly – 2026 versions fix many unfold bugs and improve K-factor handling.

Step-by-Step Beginner Tutorial: Simple Enclosure Box

1. Base Shape

Create sketch → rectangle → Use "Add Base" tool. Set thickness 1.5 mm, bend radius 2 mm.

Example of a finished parametric enclosure box with cutouts

2. Add Flanges & Bends

Select edge → "Make Wall" or "Flange" → Set height, angle (90°), offsets.

Complex chassis with multiple walls and bends

3. Holes, Cuts & Reliefs

Use Pocket or SheetMetal "Extruded Cutout" → Add corner reliefs for clean unfolds.

Unfolded part showing bend lines, holes and relief cuts

4. Unfold & Export

Select part → "Unfold" → Export flat pattern as DXF for production.

Realistic enclosure ready for cutting – side view

FreeCAD SheetMetal vs Commercial Tools – 2026 Comparison

Feature	FreeCAD SheetMetal (2026)	SolidWorks / Fusion 360
Cost	100% Free forever	$300–$5000/year subscription
Unfold / Flat Pattern	Excellent – bend lines, K-factor, DXF export	Very good, but locked behind paywall
Parametric Changes	Full – edit sketch or properties anytime	Full, but slower on complex models
Learning Curve	Medium (great community tutorials now)	Lower initial, but steep for advanced
Export Formats	DXF, STEP, STL, IGES – all free	Similar + proprietary formats
Best For	Hobby, startups, education, small shops	Large companies with budget

Final Verdict: FreeCAD Sheet Metal in 2026

Yes – it's now production-ready for most users. Zero cost, active development, huge community. Start with the tutorial above and build your first part today!

More tips & tricks → FreeCAD Extreme Blog

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

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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