You're estimating blank size during concept freeze and you google "sheet metal blank size estimation early design". A 1.2 mm thick mild steel bracket has a flat pattern area of about 0.18 m² and density 7850 kg/m³. Before nesting or scrap factor, what mass should you carry into the cost model?

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1.7 kg is the sanity check value. Area 0.18 m² times thickness 0.0012 m gives volume 2.16e-4 m³. Multiply by 7850 kg/m³ and you're at ~1.7 kg. The trap is skipping thickness or pre-loading scrap before you even have nesting.

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