I am beside myself trying everything I know to build this shape into a sheet metal part. I have drawn it a as a part file an have built it out of brass shim stock.
Part thickness 0.005"
Can anyone help or give advice.
I certainly can understand you being beside yourself. The only thing I could come up with is including flat areas in your base flange where your fancy tabs are going to be. Aesthetically it may not be desirable but I'm pretty sure this is the only way you can approach this. I quickly copied the profile of your tab and I may have lost something dimensionaly but you will get the idea.
I'll give that a try.
I have never seen a way to keep a part sheet metal and achieve this. The only possible way I could see it working is to use a forming tool possibly but am not 100% sure it would even work. You could make it from lofted bends as I show in the attached file but not sure it would work for you.
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