Hello Everyone!

Usually I can search & find solutions to my problems on these forums but this time I may need some assistance.

I am trying to create a sheet metal part for a project, but am having difficult due to the fact that the surfaces are 'non planar'.

I modeled the object as a solid, and would like to convert it sheet metal but receive the non planar surface error for the two sides.

The piece goes from a large base and to a tube at the end which will be welded to the sheet metal . There is a bit of a 'twist' between the side panels as the relative ratio of the base and the tube at the end are different, but it isn't very noticeable.

In practice, once the sheet metal parts are cut they should have no problem being welded into place with a little bit of gentle pressure.

I understand that it isn't possible to create sheet metal parts that contain non planar surfaces, however I was wondering if anyone has a suggestion on how I could model the part correctly as sheetmetal and run semi-accurate stress analysis.

The way I see it, I have two options:

- create the part as a piece of sheet metal and bend it, BUT I will have large gaps between the tube and the sides (which will make mating/welding the tube impossible). This will also leave the complete assembly looking unprofessional

- leave the part as a solid but then I would have no templates to cut the sheet metal

Is there a correct way to tackle this?

Thanks for the help!

I have attached the file so everyone can look at it.