&gt; &quot;yeah, you&#x27;re gonna have to take that into account.&quot;<p>What? But the software was supposed to take that into account, which is why it it supports bend allowance calculations in it!<p>(I have a tiny bit of experience with this; I designed some sheet metal thing. I somehow clued into bend allowances before doing it, even though it was my first and only one! I figured, you can&#x27;t just draw the naive shape; the metal has a bend radius. How the hell does that work? [half a day of Googling] Oh. I used a 2D drafting program that had no clue about this, so I manually drew the pattern with the allowance in it already, based on the thickness of the aluminum.)