Sheet metal unfolding

The problem

In sheet metal manufacturing, translating a 3D design into a flat pattern with the correct bending sequence is a critical step. Errors in unfolding or bend ordering lead to wasted material, production delays, and parts that don’t match specifications. Manufacturers needed an automated solution that could handle this process reliably starting from standard 3D models.

What we built

We built an application that imports a 3D sheet metal model in STEP or IGES format, automatically computes the flat pattern unfolding, and determines the optimal bending sequence for the press brake. The software analyzes the part geometry, calculates bend allowances, and generates a step-by-step folding plan that transforms the flat sheet into the target 3D shape. All geometric data — including the 2D flat pattern and bending instructions — is exported in DXF format, ready for the shop floor.

Result

The result is a complete bridge between 3D design and production: engineers get an automated, reliable workflow from model to machine instructions, reducing setup time and manual calculation errors.