Deciding to use—or simply consider—sheet metal for an application is the first step in a process. The process begins, of course, with function, which in turn dictates design. Choosing a material and gauge are critical steps that involve balancing factors like strength, weight, and cost. This is not a simple process, but it can be streamlined with the use of CAD models and finite element analysis (FEA) tools. The real test, however, is prototyping.

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