Streamlining Assembly for Sheet Metal Products

We trust that the Mechanical newsletter has been an enriching journey for designers and engineers so far. In the previous two editions, we highlighted tips and guidelines to help you seamlessly transition your products from CAD to the factory floor. Up ahead, we have more DFMA tips that you can leverage to optimize the cost, production time, and assembly process for products that involve sheet metal crafting.

Today’s Industry Updates include quantum clocks, 3D-printed fire-proof constructions, and the real mechanics of battery performance. And we also take a deeper look at the material of the cosmos with news of the largest cosmic neutral hydrogen catalog.

🎅 Interesting Engineering wishes all Mechanical minds a Merry Christmas and Happy Holidays!

INDUSTRY UPDATES

🌌 World's largest cosmic neutral hydrogen catalog unveiled, claims China
China’s five-hundred-meter Aperture Spherical Radio Telescope (FAST) unveils high-quality neutral hydrogen (HI) sources beyond our galaxy.

🔋 Panasonic's silicon powder batteries promise 10-minute EV charging
Sila's titan silicon can substantially reduce charging time and extend the range of electric vehicles (EVs).

🏠 Compact 3D printer to build fire-resistant house in California 
California's escalating wildfire crisis prompts one couple to get a fire-proof 3D-printed accessory dwelling unit (ADU).

🧑🏼‍🏫 Scientists reveal the mechanics of solid-state energy 
Researchers try to highlight the importance of mechanics in battery performance and give a more cohesive perspective on the conditions that affect SSBs.

SPOTLIGHT

Our sheet metal fabrication journey has brought us to explore Design for Manufacturing and Assembly (DFMA) guidelines and their implications on the factory floor. By adhering to DFMA guidelines, designers and engineers can make products with minimal parts count that are easy to fabricate and assemble. 

Today, we will discuss additional important considerations in making assembly and production processes more efficient and cost-effective. 

First, the most critical consideration when designing sheet metal products is keeping part counts as low as possible. Why? Because products with minimal parts are easier to assemble, less expensive, and dramatically reduce the margin of error. 

The best approach a designer should take is combining the functions of two or more parts into one. 

To achieve this, here are some of the key questions worth considering:

• Is the material selection the same for both parts?

• Do the parts serve different purposes?

• Does integration simplify maintenance? 

• What are the part’s individual electrical or thermal insulation needs?

• Will the assembly sequence be affected if the functions are combined?

Figuring out the commonalities between parts through these considerations can help combine the functions of multiple parts into one. 

Additional considerations

Ideally, the top priority for design engineers should be to build a product design requiring shorter assembly times. So, while limiting the part count is one aspect, they must also ensure these parts fit into each other easily. 

Here are some additional steps that can help optimize the manufacturing process. 

• Avoid sharp corners and points to prevent the part from breaking.

• Ensure near-net shape to reduce machine processing and production time.

• Know the standard sizes for the available tools like cutters and drills before designing sheet metal parts.

• Avoid thin surfaces, webs, deep embossments, and too many holes so that the parts can withstand processing without distorting.

• Eliminate unnecessary features to expedite production and reduce costs. 

To summarize it all, embracing DFMA guidelines in sheet metal fabrication and minimizing part counts ensures efficiency on the factory floor. Moreover, attention to manufacturing details such as material selection and functional intricacies further helps simplify assembly processes and reduce fabrication costs.

If you haven’t had a chance to read our previous guides on sheet metal fabrication using DFMA rules, click below.

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