Fabrication with Compound Angles

In my opinion, the element should be made of one piece of sheet metal


Flat:

Three types of connections: welded, puzzle, spot welding tab

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Thanks for your input. I agree that’s a very nice solution - the flat profile isn’t quite correct but presumably you are focusing on the manufacturing rather than achieving the profile required to press the beam shoe I drew?

If I tried to do it your way, without the puzzle joint, I think it would look something close to this?

You have right, but correct shape in your case is similar for this:

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Very nice :+1:

I had a similar situation.
What I did was copy each outside face (surface) and lay them out flat joining them at the fold line you might want to allow for some material in the fold . group it all together as a flat sheet push/[pull some thickness if you want. export to layout and then draw in the fold lines with a dotted line