Multi-Panel Trunking: The SolidWorks Method?

Hi all

I am contacting you because I very often work on multibody parts to make sheet metal junction ducts, made up of several panels bolted together to facilitate handling and installation.

My current method is as follows:
• I create a complete volume body,
• I connect the two openings with a smoothing,
• I model the flanges in volume,
• then I create the folds in volume according to the shape I have in mind,
• Finally, I convert my body into several panels.

The problem is that at the time of conversion, I very often:
• corners that do not close properly,
• small residual edges that prevent conversion,
• folds that do not meet neatly,
• or even some faces that completely refuse to be converted to sheet metal.

In summary, as soon as the geometry becomes a bit complex, it becomes difficult to get clean panels that fit well together.

So I wanted to know how you proceed for this type of part and if you have any tips, methods or best practices to share to make this work in SolidWorks reliable.

Thank you for your help.

image

Typical example