MetalCalculate - Sheet Metal Quote

Step-by-step process

Get precise quotes in minutes, not days. Here is how the experience works from uploading your file to confirming the order.

1

Upload CAD file

Access the portal and drag your design file. The system accepts DXF, DWG and STEP formats. In seconds, the geometry analysis engine identifies outer contours, inner perforations, radii, complexity and part dimensions.

2

Configure part

Select the material (steel, stainless, aluminum, galvanized...), thickness, desired quantity and additional processes: bending, threading, countersinking, surface finishes. Each option updates the price in real time.

3

Instant quote

The calculation engine uses real TRUMPF machine parameters: laser power, cutting speed by material and thickness, piercing times, acceleration, intelligent nesting on the sheet and material costs. The result is a real price, not an estimate.

4

Confirm and order

Review the complete quote, download a professional PDF with your branding and, if satisfied, confirm the order directly. You receive the order with all technical information ready for production.

Design guide

Sheet metal laser cutting

To obtain maximum quality parts, it is essential that your design meets the capabilities and limitations of the laser cutting process. This guide will help you prepare optimized files and avoid common errors.

File formats for 2D cutting

For flat parts (cutting only, no bending) we work with 2D vector files. These formats guarantee the geometric precision required for laser cutting.

.DXF

DXF

Industry standard format. Compatible with AutoCAD, SolidWorks, Fusion360 and most CAD software. Recommended.

.DWG

DWG

AutoCAD native format. Fully supported. Make sure the file contains only the part entities.

.STEP

STEP / STP

For 3D parts with bending. The system automatically unfolds the part and detects bend lines.

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Tip

Make sure your file contains only the part geometry. Remove auxiliary layers, dimensions, title blocks and any element that is not part of the cutting contour. Each file should contain a single part.

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Unsupported files

Raster images (JPG, PNG, BMP), PDF files with embedded images and STL files are not supported. STEP files exported from STL lose geometric precision and will be rejected.

Geometry and tolerances

Fiber laser cutting is perpendicular to the sheet surface. All geometries must be designed taking this fundamental restriction into account.

✅ Correct

• Closed contours without duplicates
• Connected lines and arcs (no gaps)
• Geometry at 1:1 scale in millimeters
• Perforations designed on the flat face

❌ Avoid

• Open or gapped contours
• Overlapping or duplicate lines
• Entities on hidden layers
• Angled perforations or edge perforations

Contours: correct closed vs. gaps and duplicate lines

General laser cutting tolerances

Parameter	Typical value
Dimensional tolerance	± 0.1 mm
Kerf width (cut slot)	0.1 – 0.3 mm depending on thickness
Positioning repeatability	± 0.03 mm
Cut roughness (Ra)	3.2 – 12.5 µm depending on material

Perforations and minimum diameters

Each perforation begins with a laser piercing. To guarantee hole quality, there is a minimum diameter that depends on the material thickness.

Minimum perforation diameter by thickness

Sheet thickness	Steel / Stainless	Aluminum / Copper
0.5 – 1.0 mm	≥ 0.5 mm	≥ 1.0 mm (= thickness)
1.0 – 2.0 mm	≥ 1.0 mm	≥ thickness
2.0 – 4.0 mm	≥ 1.5 mm	≥ thickness
4.0 – 8.0 mm	≥ 2.0 mm	≥ thickness
8.0 – 15.0 mm	≥ thickness × 0.8	≥ thickness × 1.2
> 15.0 mm	≥ thickness	Consult

Minimum perforation diameter vs. sheet thickness

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General rule

For aluminum and copper, use as a reference that the hole diameter (d) must be equal to or greater than the sheet thickness (t). This avoids excessive taper and ensures clean perforations: d ≥ t

Texts, signage and engravings

If your design includes letters, numbers or logos, it is essential that the text is converted to vector outlines before uploading the file. Otherwise, the system may interpret the typography incorrectly.

Cut text (stencil)

Letters are cut from the sheet. Pay attention to closed letters (A, B, D, O, P, Q, R...) as their inner islands are lost if you do not add connecting bridges.

Stencil typography with bridges vs. normal

Engraved text

The laser marks the surface without cutting through completely. Ideal for numbering, logos and traceability. Available depending on material and thickness.

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Always convert to outlines

In your CAD software: select the text > "Convert to curves / outlines / polylines". If the text arrives as an editable font, the system will not be able to process it correctly.

Micro-joints

Micro-joints are small connections (0.1 – 1.0 mm) that keep the part attached to the sheet during cutting. They prevent small or thin parts from falling into the machine pit or moving during the process, which could cause collisions with the cutting head.

When are they applied?

The system adds them automatically on parts that, due to their geometry or size, require them. They are almost imperceptible and do not affect part functionality. If you need certain areas free of micro-joints, you can indicate this in the configuration.

Subsequent removal

Micro-joints are easily removed with light pressure or with a file. If you want parts completely free of micro-joints, consult availability as it may require a parameter adjustment.

Cutting density and thermal deformation

When a design has many perforations close together or very thin geometries, the high concentration of laser thermal energy can cause deformations in the part. This is one of the most frequent causes of quality problems.

✅ Optimized design

• Distance between contours >= material thickness
• Sufficiently wide material bridges
• Balanced distribution of perforations

⚠️ Deformation risk

• Distance between contours < 8 mm
• Very thin ribs or tabs
• Very dense repetitive patterns

Cutting density: adequate separation vs. thermal deformation

Design guide

Sheet metal bending

Bending transforms a flat part into a volumetric part. With the right configuration, you can achieve complex parts with multiple bends without welding.

Air bending method

The system calculates bending times and costs using the "air bending" method, the industry standard for CNC press brakes. In this process, a punch presses the sheet against a V-die, generating the desired angle without the material fully touching the bottom of the die.

Air bending: punch, sheet, V-die, angle and radius

CNC press brakes

Digital angle control with +/- 0.5 degree precision

Multiple angles

Bends from 30 to 175 degrees depending on material thickness

Special tooling

Specific tools for each thickness and geometry

Internal radii and angles

In air bending, the inner bend radius is determined by the material thickness and the die opening. As a general rule, the inner radius should be equal to the sheet thickness.

Recommended internal radius

Thickness (t)	Min. internal radius (r)	Supported angles
0.5 – 1.5 mm	r = t	30° – 175°
2.0 – 3.0 mm	r = t	30° – 170°
4.0 – 6.0 mm	r = t	45° – 165°
8.0 – 10.0 mm	r = t × 1.2	60° – 160°
> 10.0 mm	Consult	Consult

Internal radius r=t correct vs. r=0 incorrect

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Aesthetic radii and curvatures not supported

Air bending generates bends with a defined radius, not progressive curvatures. If your design needs continuous curved surfaces, a different process is required (rolling or calendering).

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Bends without radius = file rejected

If your 3D file (STEP/STP) contains bends with zero radius (sharp edges), it will be rejected. Make sure to model all bends with the inner radius equal to the thickness (r = t).

Minimum bending distances

For the punch and die to work correctly, there is a minimum distance between the bend line and other elements of the part (edges, holes, other bends).

Minimum distances

Restriction	Minimum distance
Min. flange length (edge to bend line)	≥ 3 × t + r (never < 8 mm)
Hole to bend line distance	≥ 3 × t + r
Distance between two parallel bends	≥ 6 × t + 2r
Slot/cut to bend line distance	≥ 3 × t + r

t = sheet thickness · r = inner bend radius

Minimum bending distances: flange, holes, between bends

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Holes near the bend?

If you need a hole within the minimum bending zone, a common solution is to design a bend relief: a small slot on the bend line on both sides of the hole that allows the material to deform without affecting the perforation.

Supported file formats

Quick summary of all compatible formats depending on the type of part you need to manufacture.

Flat parts — Cutting only

2D vector files

.DXF AutoCAD, SolidWorks, Fusion 360 Recommended

.DWG AutoCAD native

Dimensions are read directly from the file. Make sure the scale is 1:1 in mm.

Bent parts — Cutting + Bending

3D CAD files

.STEP Universal 3D standard Recommended

.STP Alternative STEP extension

Thickness is read from the 3D model and cannot be modified in the configurator. Each file must contain a single part (no assemblies).

Available materials and thicknesses

The system supports the most common materials in sheet metal manufacturing. Cutting parameters are optimized for each material-thickness combination.

Fe

Carbon steel

S235JR / S355JR / DC01

The most versatile and economical material. Ideal for structures, brackets, housings and industrial parts.

Thicknesses: 0.5 – 25 mm

Cr-Ni

Stainless steel

AISI 304 / AISI 316

Superior corrosion resistance. For food, chemical, pharmaceutical, architectural and decorative applications.

Thicknesses: 0.5 – 20 mm

Al

Aluminum

AW5754 / AW6082 / AW1050

Lightweight and corrosion resistant. Ideal for electronics, aerospace, automotive and weight-critical applications.

Thicknesses: 0.5 – 15 mm

Zn

Galvanized steel

DX51D+Z275

Anti-corrosion protection through zinc coating. For exteriors, HVAC, brackets and coverings.

Thicknesses: 0.5 – 4 mm

Cu

Copper

Cu-DHP / CW024A

High electrical and thermal conductivity. For electronics, conductors, decorative parts and heat sinks.

Thicknesses: 0.5 – 6 mm

CuZn

Brass

CuZn37 / CW508L

Copper-zinc alloy with golden finish. For decoration, signage, instrumentation and industrial jewelry.

Thicknesses: 0.5 – 5 mm

Frequently asked questions

How accurate are the generated quotes?

The quotes are based on real TRUMPF machine parameters: cutting speeds, piercing times, accelerations and nesting data. The typical deviation from actual production time is less than 5%, well below manual estimation methods that can deviate 20-40%.

Can I use the system if I do not have TRUMPF machines?

The calculation engine is optimized for TRUMPF machines, but the cutting parameters are configurable. You can adjust speeds, piercing times and correction factors to adapt the calculations to your specific machinery.

Can my customers see the nesting of the parts?

You can configure whether the customer sees the nesting view on the portal. Some manufacturers prefer to show full transparency (including material utilization), while others only show the final price.

Does it support parts with multiple bends?

Yes. The system analyzes the STEP file, automatically detects bend lines, unfolds the part and calculates the time and cost of each individual bending operation. It supports multiple bends, counter-bends and angle combinations.

What additional processes can be included?

In addition to cutting and bending, the system can include in the calculation: threading, countersinking, laser engraving, deburring, surface finishes (shot blasting, brushing) and post-treatments. Availability depends on each workshop configuration.

How does the white-label portal work?

Each customer receives a portal with their own brand: logo, colors, custom domain and contact details. End customers access the portal without seeing the MetalCalculate brand — for them it is your workshop tool.

Create your quote quickly

Material Nesting

Order Summary

Upload CAD file

Configure part

Instant quote

Confirm and order

DXF

DWG

STEP / STP

Cut text (stencil)

Engraved text

CNC press brakes

Multiple angles

Special tooling

Create your quote quickly

Material Nesting

Order Summary

Uploading files...

Configure Part

How It Works

Step-by-step process

Upload CAD file

Configure part

Instant quote

Confirm and order

Sheet metal laser cutting

File formats for 2D cutting

DXF

DWG

STEP / STP

Geometry and tolerances

General laser cutting tolerances

Perforations and minimum diameters

Minimum perforation diameter by thickness

Texts, signage and engravings

Cut text (stencil)

Engraved text

Micro-joints

When are they applied?

Subsequent removal

Cutting density and thermal deformation

Sheet metal bending

Air bending method

CNC press brakes

Multiple angles

Special tooling

Internal radii and angles

Recommended internal radius

Minimum bending distances

Minimum distances

Supported file formats

2D vector files

3D CAD files

Available materials and thicknesses

Carbon steel

Stainless steel

Aluminum

Galvanized steel

Copper

Brass

Frequently asked questions