The Best Ways to Design Sheet Metal Countersinks


Sheet metal countersinks provide an attractive way to secure two manufactured parts together. Often, it’s a requirement to have hardware flush with the surface of a part, and that’s when it makes sense to design a countersink. Your sheet metal project will determine the best design and the steps you should follow can be surprisingly detailed. It is also important to consider standard dimensions for countersinks.

Countersink Dimensions

You have a lot to think about:

  • The angle of the opening
  • The large diameter of the hole that the screw fits into, and
  • The small diameter that ultimately allows the screw thread to fit snugly into the sheet metal

Two Ways to Create a Countersink

It’s all about balancing accuracy and timing.

  • For greater accuracy: We use a drill bit to form the hole, but that takes more time.
  • For speed: We form the sheet metal using a punch tool. It presses an existing hole in the sheet metal, creating the familiar countersink shape.

This video will help you learn the standardized parameters and processes that can help us turn your designs into final pieces, quickly and accurately.


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For more helpful sheet metal design tips, download our Design for Manufacturing (DFM) Guide.

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