Sheet metal manufacturers are no strangers to the complexities of modern production demands. When faced with the task of producing 3D assemblies composed of numerous components—some with intricate bevels, custom bending requirements, and specialized materials—delays and inefficiencies are common. Every 3D assembly received from customers presents a potential challenge: converting it into actionable, production-ready formats without compromising precision.
This challenge isn’t just about handling the design itself—it’s about bridging the gap between diverse CAD formats, unfolding sheet metal parts correctly, and ensuring that production teams can work with the resulting data without errors or costly delays. The stakes are high: a single mistake in unfolding or interpreting bend radii can lead to production bottlenecks, waste, or expensive rework. The traditional approach of manually decomposing assemblies, identifying components, and unfolding them into 2D files is not only time-consuming but also prone to human error.
Let’s take a closer look at why these pain points persist and how they impact the efficiency of sheet metal operations.
The Bottleneck of Manual Processing
3D assemblies often arrive in a design-oriented format that is not optimized for production. Engineers are tasked with manually processing them, identifying individual components such as bend parts, panels, screws, brackets, or structural parts or handling quantities. This process involves:
Each step is labor-intensive and relies heavily on accumulated knowledge of materials, thicknesses, and bending behaviors. Many manufacturers maintain internal tables and formulas for bend deductions or K-factors, often built on years of production experience. But even with this expertise, manual processes expose manufacturers to risks—especially when CAD formats vary or when specific bending characteristics aren’t fully documented.
Format Fragmentation: The CAD Compatibility Dilemma
A major barrier to managing 3D assemblies is the fragmentation of CAD formats. Manufacturers often receive models designed using different software, such as SolidWorks®, CATIA®, or Inventor®, each with its own unique specifications and attributes. Without a universal format, manufacturers frequently ask customers to reformat designs or manually convert them loosing thereby critical information, consuming valuable production time and increasing the risk of interpretation errors.
Moreover, when assemblies include a mix of structural materials and fasteners (such as screws or nuts), misidentifying these components can cause errors during nesting, machining, production planning, or even cost estimation.
The A2N (Assembly to Nesting) Solution: Precision, Speed, and Integration
Lantek’s Assembly to Nesting (A2N) module directly addresses these issues by providing an automated workflow for processing 3D assemblies efficiently and with minimal error risk. A2N’s key advantage lies in its ability to directly import 3D files from leading CAD platforms, eliminating the need for manual format conversions and enabling error-free production.
A2N supports standard CAD formats such as IGES, STEP, and ACIS, as well as native formats from the industry’s most widely used 3D CAD systems, including SolidWorks®, Solid Edge™, Inventor®, CATIA®, CREO®, and Siemens NX. This direct import capability requires no intermediate steps. Once imported, sheet metal parts are automatically unfolded and converted into 2D files, applying preconfigured bend deductions tables or K-factors specific to each material. Historical production data and custom formulas can be integrated into the system, ensuring highly accurate results delivered at a speed far beyond manual methods.
The system also automatically detects bevels in 3D models and processes their information for machining on laser or plasma cutting machines, tubes and beams are analysed and processed. Additionally, it optimizes cuts, corners, and slots to ensure compatibility with both cutting and bending processes. Seamless integration with other systems, such as Lantek Expert and Lantek Flex3D, allows unfolded assemblies to be easily managed within existing production and nesting workflows.
Meeting the Industry’s Specific Needs
A2N addresses key challenges in sheet metal manufacturing by reducing errors, accelerating production, and optimizing cost estimation processes. By automating complex tasks such as unfolding with specific bend deduction and material compensation, A2N minimizes inaccuracies that would otherwise cause production issues and unwanted material waste. Tasks that once required hours of manual effort—unfolding components, recalculating tolerances, and reformatting files—can now be completed in minutes, enabling manufacturers to meet tight deadlines without disrupting ongoing production.
Additionally, A2N integrates seamlessly with Lantek Integra Quotes, automatically feeding manufacturing data into the quotation process, eliminating uncertainty, and speeding up responses to customers. In an environment where efficiency and cost control are critical, automation is no longer optional. Tools like A2N not only address today’s demands but also prepare manufacturers to thrive in a digital, data-driven future. With its ability to improve processing speed, reduce production times, and unify diverse CAD systems into a cohesive production process, A2N offers a scalable solution that blends productivity and precision.