How do I resolve the ‘No Bends Found’ SOLIDWORKS Sheet Metal Error?

Have you ever received this SOLIDWORKS Sheet Metal Error?

“No bends found.”

No Bends Found SOLIDWORKS Sheet Metal Error

Why do I get this error?

This is a common sheet metal error I used to see all the time. This typically occurs when you are converting a solid body part into a sheet metal part using the Insert Bend feature. There are limitations to the gap size when converting. If you are concerned about the gap size being too large then this article is for you.

Sheet metal bent state

A solution to the problem

I have an easy example part that is 48″ in diameter, but the smallest gap I could get (without going crazy into decimals) was a 0.004″. With the Flatten feature the total diameter is 150.3998″.

Flattened State

This is what I do to get a smaller gap. I start a sketch on the right plane and use the 3 Point Arc command. I then draw two construction lines and connect the arc to the origin. Here is where you can dimension a tiny gap of 0.0001″ to the arc construction lines. Below is my example of the arc and a closeup of the construction line dimension.

Close-up of split

Sheet metal sketch

With this sketch I went straight into the sheet metal Base Flange command and made the same mid-plane 48″ length like the first part. Be careful when using the single line sheet metal, make sure your material is going in the right direction – if its not, you can use the Reverse Direction check box. The flattened length of this part is 150.4046. It is slight 0.0038″, but if you are concerned about getting the gap smaller then use this technique.

Correct flat pattern