Sheet Metal Design

Hello,

I've been struggling with, and working around, making accurate prints for formed round bar stock. I used to gather linear length and measure to each bend radius center to find close parameters to form to.

I then discovered I could fool the sheet metal functions by make a square extrusion, bending with the sheet metal function, then adding fillets to get my rounded OD. I had to arrange them in configurations to appease solidworks. The flat pattern configuration won't allow fillets, which is fine because you can't tell on the print, the second configuration is formed with fillets. It works, but I still feel like it's a sloppy way to model a part.

Does anybody have a better solution to this issue?

Much thanks. Pictures and part file attached for reference.

Grabcad model

Flat Pattern Round Bar

Used to illustrate manipulation of sheet metal function to generate bend lines on round bar stock.