Sheet Metal Cut Size Calculator

Calculate a practical sheet metal flat blank size from finished dimensions, bend allowance or bend deduction, with optional trimming and cutting allowances.

Calculation method

Use Bend Allowance when you know the developed bend length. The flat length is calculated by adding the bend allowance to the straight finished sections.

Finished dimensions

Bend information

Enter the allowance or deduction from your bend calculation, tooling data or shop standard.

Cutting allowance

These allowances are optional practical additions for trimming, cutting or setup. Set them to zero when they are already included in your shop dimensions.

Calculated cut size

Flat length
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Flat width
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Blank area
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Bend contribution
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Calculation details

Enter the dimensions and calculate.

Formula

Flat length = finished length + finished flange/width + total bend allowance + cutting allowance Total bend allowance = number of bends × bend allowance per bend Blank area = flat length × flat width
Actual flat-pattern dimensions depend on material, thickness, inside bend radius, K-factor, tooling, bend method and machine setup. For production-critical parts, verify the result against your shop's proven bend data.

Example

Finished dimensions
300 mm length × 100 mm flange.
One bend
Bend allowance = 20 mm.
Flat size before cutting allowance
300 + 100 + 20 = 420 mm.
With 3 mm cutting allowance
420 + 3 = 423 mm flat cut length.

Frequently Asked Questions

What does this calculator determine? It estimates the flat sheet blank dimensions required before bending a simple sheet metal part.

What is bend allowance? Bend allowance represents the material length consumed through the bend and is normally measured along the neutral axis.

What is bend deduction? Bend deduction is a shop-friendly method for determining the flat blank from finished flange dimensions.

Why does thickness matter? Material thickness affects the neutral-axis position, bend radius and therefore the developed flat length.

Can this calculate complex sheet metal parts? This calculator is intended for simple dimensions with a known total bend allowance or bend deduction. Complex multi-bend profiles should be developed using dedicated sheet-metal CAD or validated bend tables.

Should kerf always be added? No. Only add a cutting allowance when your manufacturing process requires it and it is not already included in the supplied dimensions.