Designing Parts for Laser Cutting and Press Brake Forming

In metal fabrication, great results start with great design.

Many production issues—delays, rework, and unnecessary costs—can be traced back to how a part was originally designed.

If you’re designing parts for laser cutting and press brake forming, a few simple guidelines can make a significant difference in both cost and manufacturability.

1. Account for Bend Allowances

When metal is bent, it stretches.

If bend allowances aren’t properly calculated:

• Parts may end up too short or too long

• Assemblies may not fit correctly

👉 Always design using the correct bend allowance or bend deduction for your material and thickness.

2. Keep Holes Away from Bend Lines

Placing holes too close to a bend can cause:

• Hole distortion

• Cracking

• Dimensional inaccuracies

Best practice:
Keep holes at least 1.5x material thickness away from bend lines.

3. Use Standard Bend Radii

Tight bend radii can:

• Increase tool wear

• Cause material cracking

• Slow down production

👉 Using standard radii improves consistency and reduces cost.

4. Design for Laser Efficiency

Laser cutting is extremely precise—but design still matters.

To improve efficiency:

• Avoid excessive small features

• Standardize hole sizes

• Reduce unnecessary complexity

Simpler designs = faster cutting = lower cost.

5. Consider Material Grain Direction

For certain materials, bending against the grain can increase the risk of cracking.

👉 When possible, align bends with the grain direction for improved results.

6. Plan for the Full Fabrication Process

Design isn’t just about cutting—it’s about the entire workflow:

• Laser cutting

• Forming

• Welding

• Powder coating

Thinking through the full process helps avoid:

• Fit-up issues

• Rework

• Delays

7. Partner with Your Fabricator Early

One of the most overlooked advantages:

👉 Involving your fabrication partner early in the design process

This can lead to:

• Lower costs

• Better manufacturability

• Faster production timelines

Design + Fabrication at Dole Fabricating

At Dole Fabricating, we work closely with customers to ensure designs are optimized for production.

Our capabilities include:

• High-precision fiber laser cutting (4kW, 8kW, 10kW)

• CNC press brake forming

• Welding and powder coating

• An ISO-registered quality system

By combining engineering insight with modern equipment, we help customers move from concept to finished part efficiently and reliably.

✔ Have a design you’d like reviewed?
Our team is happy to provide feedback to improve manufacturability and reduce cost before production begins.