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Sheet metal original and improved bending radius design as shown below: Of course, the sheet metal bending radius is not the bigger the better. The larger the bending radius is, the larger the bending spring back is, and the bending angle and bending height are less easy to control. Therefore, the radius of the sheet metal needs reasonable value. The bend allowance and bend deduction are two measures that relate the bent length of a piece of sheet metal to the flat length. The bend allowance describes the length of the neutral axis between the bend lines, or in other words, the arc length of the bend. Nov 23, 2009 · For hems (a bend of 180 degrees), it's highly desirable to use at least one material thickness for most alloys in this size range, and essential for aluminum. For more complex formed features such as stiffening detents, talk to your sheet metal part supplier. But none of this is carved in stone. There should have bending radius for sheet metal bending, bending radius should not be too large or too small, it should be chosen appropriately. If the bending radius is too small, it will cause cracking at the bend position; if the bending radius is too large, it is easy to rebound. Recommended inside bend radius for sheet metal parts should be equal to material thickness. But for harder materials ( e.g. CRCA) inside bend radius equal to 0.65 times of sheet thickness is also enough. Bend radius throughout the sheet metal design is kept constant to take the advantage of using same tool during manufacturing. Sheet Metal Bend Allowance. When a piece of sheet metal goes through the process of bending, its upper layer (with inside radius) is compressed and the lower layer (with outside radius) is stretched. Due to this tension and compression, the length of the sheet metal piece increases.