An opportunity is found to reduce setup time in sheet metal panel bending tasks by deliberately leaving gaps between a segmented punch to allow passage of a bent flange or to adjust the distance between articulated die sections for reentrant bends. The effects of this practice on part appearance and dimension is addressed to assure part quality. The gap/thickness ratio is found to be an indicator of part geometry and subjective quality. A zero setup punch and die set is described for four-bend parts.

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