Okay, for:

I have a request for straps, which brings the whole question of bending metal to the fore.

@luc.onthego found a great video on this mentioned at:

and I hope @themillertree will chime in.

Thus far I’ve been quite simplistic in my handling of this:

- cut off at the desired angles
- “bend” at the midline of the material
- round off the outside edge with a cylinder

and my question is — what are the calculations and needed parameters for this?

Assuming one wants:

(actually cut out of angled stock, but you get the picture)

then what is the profile one needs to cut?

It can’t be the simplistic:

but how would it deviate from the:

which I described above and is what I am currently modeling?

I’m thinking as a first approximation rather than halving the thickness I divide it into thirds and round the bottom of the channel (hey! I have a BitSetter, I should use it, right?):

which when zoomed in is:

Anyone have some useful guidelines, links, or numbers?