Sheet Metal Cone Development Calculator

Calculate the flat pattern for a straight cone or truncated cone from top diameter, bottom diameter and vertical height.

Cone type

For a truncated cone, enter both top and bottom diameters. The calculator develops the shape as an annular sector.

Cone dimensions

Manufacturing allowances

These allowances are added to the developed radial dimensions for fabrication. Set them to zero when your shop uses separate seam or trim dimensions.

Calculated Results

Outer development radius
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Inner development radius
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Sector angle
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Bottom developed arc
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Top developed arc
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Blank area
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Development Details

Enter dimensions and calculate.

Formula

For a truncated cone: R = bottom radius r = top radius H = vertical height Slant height: L = √[H² + (R − r)²] Outer development radius: Ro = L × R / (R − r) Inner development radius: Ri = L × r / (R − r) Sector angle: θ = 360 × R / Ro Bottom developed arc: Ab = 2πR Top developed arc: At = 2πr For a full cone: Slant height: L = √[H² + R²] Sector angle: θ = 360 × R / L
This is the geometric development of a right circular cone or frustum. Real fabrication may require seam, trimming, weld, lock-seam, rolling and material-specific allowances.

Example

Finished frustum
Bottom diameter 300 mm, top diameter 150 mm and vertical height 250 mm.
Radii
Bottom radius = 150 mm. Top radius = 75 mm.
Slant height
√(250² + 75²) ≈ 261.01 mm.
Development
The calculator uses the similar-triangle relationship to determine the outer radius, inner radius and sector angle of the annular flat pattern.

Frequently Asked Questions

What is cone development? Cone development converts the three-dimensional cone or frustum into a two-dimensional flat pattern that can be cut from sheet material.

What is a cone frustum? A frustum is a cone with its tip removed, leaving two circular ends of different diameters.

Why is the development an annular sector? A truncated cone unwraps into a portion of a ring, creating an outer arc and inner arc.

What happens when the top diameter is zero? The frustum becomes a full cone, and its development becomes a single circular sector rather than an annular sector.

Does sheet thickness change the geometric result? The geometric development is based on the supplied finished diameters and height. Manufacturing thickness, forming and joining allowances may require separate adjustments.

Can I use this for ducts and hoppers? Yes, for straight circular cones and frustums where the sides are developed from a common apex.

Can this calculate an offset or eccentric cone? No. An eccentric or oblique cone requires a different development method, commonly involving triangulation or radial-line development.