Extruded Holes or Shapes

An extruded hole or shape is punched or pierced through the metal and typically has a protruding
lip on the bottom or back side of the material. The distance of the protruding lip can vary
dependent on the punch and die configuration. This protruding lip adds a resistance to bending
and twisting to the parent material.

 The minimum distance between two extruded holes is six times the material
thickness.
 The minimum distance from an extruded hole to an edge is three times the
material thickness.
 Only rounded shapes may be extruded or punched. Shapes with angles will
distort or tear the sheet metal.
 Refer to images B & C below for the minimum distance from an extruded hole
to a bend.
 It is a bad practice to place an extruded shape on a bend. The bend would distort
the extruded shape or vice versa. (refer to image A below)

Gussets

A gusset is typically a triangular shaped flat plate used to connect and reinforce a joint where
several members meet at different angles.

 The width and depth, recommended at an angle of 45 degrees, is directly

proportional to the radius and material thickness.
 The minimum distance that a gusset/dart should be from the edge of a hole in a
parallel plane is eight times the material thickness plus the radius of the gusset.
Hems

A hem is a 180° bend that is performed to, remove sharp edges, connect two pieces of metal, and
produce a finished edge on a work piece. This is commonly found on the bottom of doors.