Folded Sheet Aluminium Wheel Guards — KT Kustoms
Folded 3mm aluminium wheel guards modelled in the Fusion 360 sheet metal workspace, flat-patterned for laser cutting with the KT Kustoms logo cut through the top face.
Overview
A pair of trailer wheel guards developed for KT Kustoms as a laser-cut and folded sheet metal part, so the entire form had to unfold cleanly to a single flat blank. The guards were modelled in the Fusion 360 sheet metal workspace, with a 600 mm top face, 120 degree shoulder bends and 290 mm and 410 mm legs, plus tapered corner reliefs at each fold line. Four slots in the top face allow mounting adjustment, and the KT Kustoms logo is cut straight through the crown. The flat pattern was released as a folding drawing in 3mm aluminium, with a polished variant and a plain no-logo version.
Key Features
Designed in Fusion 360 sheet metal workspace with correct bend allowances
3mm aluminium sheet specified for the production run
Slotted mounting holes allow adjustment across mounting positions
Optional KT Kustoms logo cutout as a variant of the flat pattern
Tapered side skirts formed by 45 and 60 degree folds
Specifications
- Material
- 3mm aluminium sheet
- Software
- Fusion 360 sheet metal workspace
- Fabrication
- Laser cut flat blank, press folded
- Dimensions
- 600 mm top face, 290 mm and 410 mm legs
- Bends
- 120 degree shoulders, R3 bend radius
- Finish
- Polished
Design Process
Set out overall guard geometry and coverage requirements
Model the guard in Fusion 360 sheet metal workspace
Define bend angles and R3 radii across the fold lines
Position mounting slots and optional logo cutout
Flatten to a production flat pattern for laser cutting
Produce dimensioned drawings and folding sheet for fabrication
Gallery
