Custom headache rack design

I am designing a lightbar/headache rack using 1/2" aluminum. Any thoughts or suggestions on the design? Probably use an online service like xometry to laser cut and bend. Not sure on price yet.

 

I hope the online service has the correct die to bend that and not have it crack... Aluminum that thick can be tricky.

Also, there is a chance the tapered edges of that will want to ?blow out? when its bent.

Besides those two points it looks cool!!!

 

General thoughts:
The overall design looks OK, but maybe a little small? Looks like it could use another inch (TWSS) along the angled back sides of the sail panels and across the top rail.
I know that much 1/2" aluminum won't be ultra-light if that's of any concern.

If I was going to mass produce these I certainly wouldn't be making it all one piece. Bolt together with high quality hardware.
I see 7 distinct parts: Bed rail bracket (X2), vertical sails (X2), radiused corner joiner (X2), and top rail (X1).
The rail brackets could be a thinner extrusion in order to better work with tonneau covers.
The top rail would likely need a stiffening rib along the underside to keep it from bowing.
Which would likely necessitate raising the top rail higher so that the rib wouldn't block the CHMSL and box light.

 

Looks similar to the Diamondback HD Cab Guard. This one has a mesh to protect the back window.

I agree that it needs to be taller. I wouldn't want to hit the sharkfin with materials. If I had 2 of your racks (front and back) for carrying long items like my 30' extension ladder or some 12' lumber, etc...

 

Makes it look like an Avalanche……

 

1/2" is thick for bending. You'll likely end up with surface marring.

Also, the bed interface is wrong. You have an exterior 90deg and far too tight of a bend radius. The min I'd shoot for would be 4T.

 

Ya or an older Honda Ridgeline. I had this DB Cab Guard on my Ridgeline to make it look like an older version.