Xeon Onshape Minimal gap comparison - captured September 5, 2026

Original screenshots were captured directly from the Onshape application.
JPG files retain the capture bytes. The corner images are equal 300 x 290
screen captures of the front-right corner; full screenshots are 1419 x 982.
WebP files are web display encodings of the originals, not synthetic renders.

Only Minimal gap changed between these three copied Part Studios:
07 Minimal gap - 0.005 in: ac63eb52d68e6095f1548b24
08 Minimal gap - 0.025 in: d9e87eaa79ebf9ce4aaf2fa6
09 Minimal gap - 0.125 in: 7c37064794d1bb09512ee9e7

Document: b6bbf490fab67fdb9450b8d8
Workspace: 7fe33ec1809afc94a7169373
Original source: 02 Rectangle - Scaled 1.5

Fixed controls read from each Sheet metal model feature:
Thickness: 0.125 in
Inside bend radius: 0.125 in
Bend calculation: Bend allowance
Default bend K Factor: 0.4
Rolled K Factor: 0.5
Corner relief type: Rectangle - Scaled
Corner relief scale: 1.5
Bend relief type: Obround - Scaled
Bend relief depth scale: 2
Bend relief width scale: 1.063
Clearance from input: 0 in; Flip direction up enabled.
Other joints: Rip / Edge joint. Four bends at 90 degrees.

The original box was prepared as the 11 x 6 x 2.5 inch 5052 example.
This CAD-only comparison keeps its original bend data. It is not the current
catalog tooling setup (0.189 inch radius, K 0.44 for 0.125 inch 5052-H32).

Observed: all three configurations regenerate a folded box and a flat pattern.
The widest setting visibly opens the vertical seams. The narrower seams can
look closed at this zoom. The fixed relief controls do not imply invariant
cutout geometry when the adjacent seam changes.

Not measured: actual cut width, tolerance accumulation, forming interference,
springback, cracking, weld fit-up or physical minimum gap. No sheet was cut,
formed or welded in this test. CAD regeneration is not manufacturing validation.

File suffixes:
settings - feature dialog displaying the entered gap and fixed controls
formed   - accepted folded box
flat     - accepted folded box with sheet metal table and flat view
corner   - same screen region from the folded model for side-by-side comparison
