Hand-Operated Roof Flashing Notcher
Budget / Salary$30–250
TypeFreelance project
LocationRemote
Posted1 hour ago
I need a designer to create a compact hand-operated tool. It punches a trapezoid notch into the edge of 0.5 mm steel flashing so the flashing fits over Klip-Lok 700 roof ribs.
The cut-out
Trapezoid notch: 51 mm wide at the sheet edge, 22 mm at the top, 40 mm deep
Material: 0.5 mm Zincalume / pre-painted steel (G300–G550)
Cut in one stroke, clean edge, no tearing
Peak cutting force is approximately 15–26 kN, so the punch needs a shear angle and the lever needs real mechanical advantage
Tool outline
Overall body length approximately 250 mm. The handle can extend beyond this or be removable.
6–7 main parts:
Base / frame
Die (lower cutting insert, hardened tool steel e.g. D2)
Punch (upper cutting insert, hardened tool steel)
Punch holder / ram with guide
Lever / linkage
Handle
Stripper with edge stop and indexing pin, so notches line up at the rib spacing
Approximate die head size: 100 mm wide × 80 mm deep × 120 mm tall, including the punch guide. The die block itself is about 100 × 80 × 25 mm. The punch is about 20 mm thick.
Throat depth of at least 60 mm so the sheet slides fully under the punch
All assembly with bolts and nuts:
High-tensile (8.8) bolts at pivots
Cap screws plus dowels to locate the punch and die so they can be replaced
Mounting holes in the base for bolting to a bench
Non-cutting parts (guides, stops, covers, handle grip) may be 3D printed. The frame and cutting parts must be steel.
Deliverables
Force and lever calculation
3D CAD (STEP) of the full assembly, plus STL files for any printed parts
2D manufacturing drawings with tolerances. The punch–die clearance must be specified at about 0.03–0.05 mm.
Bill of materials, including bolt sizes
One round of revisions after a prototype test
Please include in your proposal
Similar tooling or sheet-metal die work you’ve done
Your price and timeline
The CAD software you use
Reference drawings of the notch and an example tool are available on request.
The die head size is my estimate, worked from the notch plus about 20–25 mm of steel around it. Expect the designer to refine it. Fill in your budget and deadline before posting.
The cut-out
Trapezoid notch: 51 mm wide at the sheet edge, 22 mm at the top, 40 mm deep
Material: 0.5 mm Zincalume / pre-painted steel (G300–G550)
Cut in one stroke, clean edge, no tearing
Peak cutting force is approximately 15–26 kN, so the punch needs a shear angle and the lever needs real mechanical advantage
Tool outline
Overall body length approximately 250 mm. The handle can extend beyond this or be removable.
6–7 main parts:
Base / frame
Die (lower cutting insert, hardened tool steel e.g. D2)
Punch (upper cutting insert, hardened tool steel)
Punch holder / ram with guide
Lever / linkage
Handle
Stripper with edge stop and indexing pin, so notches line up at the rib spacing
Approximate die head size: 100 mm wide × 80 mm deep × 120 mm tall, including the punch guide. The die block itself is about 100 × 80 × 25 mm. The punch is about 20 mm thick.
Throat depth of at least 60 mm so the sheet slides fully under the punch
All assembly with bolts and nuts:
High-tensile (8.8) bolts at pivots
Cap screws plus dowels to locate the punch and die so they can be replaced
Mounting holes in the base for bolting to a bench
Non-cutting parts (guides, stops, covers, handle grip) may be 3D printed. The frame and cutting parts must be steel.
Deliverables
Force and lever calculation
3D CAD (STEP) of the full assembly, plus STL files for any printed parts
2D manufacturing drawings with tolerances. The punch–die clearance must be specified at about 0.03–0.05 mm.
Bill of materials, including bolt sizes
One round of revisions after a prototype test
Please include in your proposal
Similar tooling or sheet-metal die work you’ve done
Your price and timeline
The CAD software you use
Reference drawings of the notch and an example tool are available on request.
The die head size is my estimate, worked from the notch plus about 20–25 mm of steel around it. Expect the designer to refine it. Fill in your budget and deadline before posting.
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