SolidWorks Sheet Metal Tutorial – Electrical Enclosure (STEP-BY-STEP)

Step-by-step video tutorial showing how to make a small electrical enclosure from sheet metal.

You will learn how to create a base flange, add edge flanges with k factor allowances, use stamping and forming tools, add a fan vent all using built-in SolidWorks library tools. Finally, I will show how to flatten the parts into a format which could be sent for cutting/CNC Bending or used to produce engineering drawings of the enclosure.

Total Time Approx 25min

Fix those pesky Solid part Fillet errors in Solidworks using basic Surfacing Tools

I’ve come across this problem more than a few times and never had a good solution. Sure you can mess around with variable radius fillets, or change the base geometry…. but sometimes that’s just not possible. It just has to work within the given constraints. And you either need rounded edges for manufacturing purposes, or perhaps its safety. Or maybe you just want those beautiful smooth edges that catch the light to make your product stand out in a photoshoot!

At some point this happens:


But it doesn’t have to be… It can be like this, easily:


Check out my Tutorial on YouTube below that shows how to fix this in minutes using the surfacing tools in SolidWorks:


Thanks for dropping by, stay tuned for more solidworks content on this website and my youtube channel here: BlackRock3D Youtube Channel

16 X 16 Pixel RGB LED Artboard Part 2

So continuing from Part 1 of the Series on designing and building a 16 X 16 RGB LED Artboard...

At first, I had such grandiose ideas of this stunning foam core frame for the LED panel… well this didn’t work out for me. Let me explain why.

Have you ever tried to cut intricate foam core shapes with an exacto knife… the foam either gummed up the blade resulting in horrible edges that basically ended up pulling and ripping that paper backings on both sides…

Grid design for holding WS2812B RGB LED’sI tried multiple techniques and decided life was too short, plus I have a 3D printer at my disposal!! ….. 

Look it just wasn’t my thing. So instead I went with a 3D printed design. Now I could make precise squares, with thin walls. And I could make the exact shape of the LED as  cut out and pop the suckers in…. it all made sense now and I began to come up with printable design…

With this design the LEDS simply “snap” into place on the side opposing the open face of the array.

Here’s a shot of the first piece being printed on my FDM printer:

Populating the first panel with LED’s:

Laying down copper:

Testing the first panel:

Four panels tested and ready for final connections:

After wiring all four panels together, tested finished 16 X 16 panel using Arduino Duemilanove and a 5V 4A power supply 😀

Conclusion of Series in part 3 – Programming and Finishing in Wood/Glass Frame