1. Efficient Material Selection:

   • Use common and easily machinable materials to avoid additional costs associated with specialized handling or tooling. For instance, choose standard grades of steel or aluminum that are readily available and work well with most fabrication processes.

2. Simplifying Design Elements:

   • Design parts with the least number of bends. If a part can be made with three bends instead of five, it reduces both the fabrication time and the possibility of errors.
   • Create designs with straightforward cuts and avoid intricate shapes that require extensive machine time. Straight, clean cuts are easier and faster to execute.

3. Designing for Ease of Fabrication:

   • Ensure that there’s sufficient space for tools to access all areas of the part. For welding, leave enough clearance around the joint areas.
   • If a part can be modular, design it in sections that can be easily fabricated and then assembled. This can simplify the overall manufacturing process.

4. Minimizing Assembly Complexity:

   • Incorporate features like notches or alignment tabs that help in correctly orienting parts during assembly, reducing the time and potential errors in assembly.
   • Limit the variety of fasteners used in the design. Using one or two standard sizes simplifies inventory and speeds up the assembly process.

5. Optimizing for Fabrication Processes:

   • Design with tolerances that are achievable without requiring excessive machining time. For example, allow for a tolerance of ±0.5 mm rather than ±0.1 mm if the function of the part permits.
   • Arrange parts on the material sheet in a way that maximizes material usage and minimizes waste. Consider software solutions for optimal nesting of parts.

Standard Tolerances – ISO 2768:

Our processes follow the ISO 2768 standard for general tolerances, guiding dimensional variations. For instance, if a part is designed to be 100 mm, under ISO 2768, it might vary slightly but will stay within the predefined acceptable range.

Material Sheet Tolerances:

Each material sheet, typically with a tolerance of around ±0.050 mm, affects the final dimensions. For example, a 5 mm thick steel sheet might actually range from 4.95 mm to 5.05 mm in thickness, impacting design considerations.

Different material thicknesses result in varying tolerances. Designers must account for these in their designs to ensure that assembled parts fit and function as intended.

Design Considerations for Tolerances:

When designing, both ISO standards and material-specific tolerances should be considered. For a design requiring high precision, such as a fitted component in an assembly, these tolerances become critical to ensure seamless integration.

Balancing Tolerances and Cost:

Tighter tolerances can lead to increased costs. For example, a design requiring a tolerance tighter than ±0.050 mm may necessitate additional processing, increasing manufacturing time and expense.

Communicating Tolerances in Designs:

Clearly marked tolerances on design drawings guide the fabrication team. For instance, a design might specify a hole diameter of 10 mm ±0.1 mm, directing the team on the acceptable range for drilling.

Bend Radius Guidelines:

General Rule: The minimum bend radius should typically be the same as the thickness of the material. For example, for a 2 mm thick metal sheet, a minimum 2 mm bend radius is recommended.

Material Specifics: Softer materials like aluminum can tolerate tighter bend radii, while harder materials like stainless steel require larger radii to prevent cracking.

Bend Angle Considerations:

Accounting for Springback: Different materials exhibit varying degrees of springback. For steel, overbending by 2-3 degrees is often necessary to achieve an accurate angle. Aluminum, being more flexible, may require a slightly greater overbend.

Precision in Angles: For critical components where angles are vital, prototype testing is advisable to determine the exact bending requirement.

Positioning of Bends:

Distance from Edges: Ensure bends are positioned at least two times the thickness of the sheet from any edge to maintain structural integrity. For a 1 mm thick sheet, bends should be at least 2 mm from the edge.

Spacing Between Bends: Maintain a minimum spacing between consecutive bends, typically around three to four times the material thickness, to prevent interference and ensure ease of fabrication.