The SOLIDWORKS Sheet Metal Gusset tool can quickly add various size and shaped gussets to your bent parts. In this example I have a 90deg bend, but it also works on acute and obtuse angles.
You can launch the Sheet Metal Gusset tool from either the Sheet Metal tab in the CommandManager, or Insert > Sheet Metal > Sheet Metal Gusset. First select two faces with a bend between. You can select either the two inside or two outside faces (but not a mismatch so be consistent!).
The second selection (purple) will be the direction for the position of the gusset. By default it picks up one of the linear edges on the bend. The third selection (pink) is the reference point where the gusset will be positioned. In this case it grabbed the end of the linear edge. Therefore you can give an Offset value for the distance from this point to the middle of the gusset.
You can select any reference point, not just along the bend line. For example I can pick up the origin since the part is symmetric and deselect Offset so the point will line up centered with the gusset. You could also choose the Midpoint of an edge.
The Profile can be set to an Indent Depth which is the distance from the inside fillet to the outer edge of the gusset. You can also get the Profile Dimensions for the two length dimensions and angle.
Scrolling down you have further options. The buttons at the top on the image below allows you to choose either a Rounded or Flat gusset on the top face. Then provide all of the dimensions required. Enabling the Full Preview will show the thickness and fillets before you accept.
NOTE: The Flat Pattern will ignore the gusset and just flatten the part as if it wasn’t there. The Sheet Metal functionality will not account for any stretch/deformation/thinning caused by adding a gusset.
Learn more about Sheet Metal
Take our SOLIDWORKS Sheet Metal training course either live online or in a Canadian city near you.