Maximizing Your Metal: How to Get the Most Yield from Sheet Goods

While it’s sometimes possible to order custom sheet sizes directly from a mill, that path comes with longer lead times and minimum quantity requirements. If scope and design allow, working with standard sheet sizes is the most efficient way to maintain both schedule, budget, and quality.

Understanding the Finer Points of Material Dimensions and Material Usage

Our Flat Seam Panel System involves alternating up-and-down hemmed edges on each panel. This adds roughly 3 inches to both the width and height of each panel beyond the visible surface.

For example, if your design calls for a 24″ x 72″ face dimension, the actual sheet metal cut will need to be 26.25″ x 74.25″. If you’re using a 36″ x 96″ copper sheet, this panel size may result in significant leftover material that cannot be reused, driving up both cost and waste.

By adjusting your panel dimensions slightly, without compromising your design intent, you can often nest more panels per sheet and boost yield.

Sample Yield-Optimized Panel Sizes for Flat Seam

Some efficient, low-waste panel size examples that nest nicely on a 36″ x 120″ copper sheet include:

• 20″ x 31.5″ (5 per sheet, rotated)
• 13.875″ x 36″ (6 per sheet)
• 30″ x 36″ (3 per sheet)
• 13.875″ x 115.5″ (2 per sheet)

These sizes account for hemming, kerf spacing, and other factors to ensure optimal material yield.

Balancing Panel Size with Labor and Appearance

Choosing the ideal panel size is a delicate balancing act between minimizing material waste, reducing fabrication labor, and maximizing aesthetic impact.

We help designers evaluate these tradeoffs and propose layout options that make the best use of selected materials.