Whether your sheet metal parts need the angled edge of a chamfer or the rounded edge of a radius, there are a few things you should know.

You can further your savings by removing the non-critical chamfers and radii from your 3D model, too. If you don’t do it, we will have to remove these design elements prior to programming our machines.

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ASM can achieve chamfers and radii using various methods, such as special punch tools, hand-filing, or shaping with a dual-action sander. Tumbling can be an effective way of adding a radius to your part’s edges. For chamfered and rounded edges with critical tolerances, however, machining is almost always the best—and only—solution.

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Chamfers and radii are commonly requested features in custom sheet metal fabrication that can occasionally cause confusion.

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A chamfer is a 45-degree bevel cut across adjoining right angles, commonly used to create clearance for mating parts, simplify assembly, and eliminate sharp edges. A radius, on the other hand, replaces a raw corner with a rounded edge, improving safety and aesthetic appeal, and enhancing the fit of connecting parts.

If chamfers and radii are not critical to your design, it is best not to dimension them on your print or model to avoid unnecessary costs. Instead, add a note to your print asking to “remove all sharp edges.” For critical dimensions, include them on your print, and ASM will ensure they are machined to meet precise specifications.

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ASM uses various methods to achieve chamfers and radii, including special punch tools, hand-filing, shaping with a dual-action sander, and tumbling. For edges with critical tolerances, machining is almost always the best and only solution to ensure precision and accuracy.

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Talk to our team about your next custom sheet metal fabrication project. Get started by requesting a quote, and we’ll be in touch with you soon!

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When enhanced safety and simplified assembly are important for your sheet metal parts, either chamfers or radii will do the trick. You don’t even need to dimension these features on your print or include them on your model. In fact, don’t dimension your edges—or we’ll quote you for critical dimensions you don’t actually need!

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To ensure precision and accuracy, we’ll engage our CNC machine shop to machine the chamfers or radii. Though machining does add to a part’s cost and lead time, it’s the best process for achieving critical edge specifications and preventing part rejections during inspection.

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If your sole goal is safety, the simplest way to get your part’s sharp edges removed is to ask. Just add a note to your print asking us to “remove all sharp edges”—and we will.

When we see that you’ve dimensioned the chamfers and radii on your print, we trust that those dimensions are critical and that you’ll inspect your parts in accordance with those dimensions.

If safety is your main concern, simply request to have all sharp edges removed. ASM includes deburring as part of their standard processes, which is usually sufficient to achieve smooth and safe edges without additional specifications.

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To ensure your sheet metal parts meet your requirements, use your print, model, and RFQ to communicate clear specifications and expectations. Providing detailed information allows ASM to understand your goals, recommend alternative solutions, and deliver parts that meet your needs. Contact ASM to discuss your next custom sheet metal fabrication project and request a quote to get started.

Adding chamfers or radii to a part’s edges is a smart way to improve fit, eliminate unsafe edges, and enhance the part’s aesthetic appeal. So, what’s the difference between the two features?

The number one way to get sheet metal parts made your way is to use your print, model, and RFQ to communicate clear specifications and expectations. When we thoroughly understand your goals and requirements, we’re empowered to not only achieve them but also recommend alternative solutions when we identify a better approach.

At ASM, deburring is included as part of our standard processes, so if safety is your only focus, deburred metal edges are usually considered sufficiently smooth.