Knowledge & Community For Engineers & Product Designers

Hi! I need advice on optimizing the design of a part that will be CNC machined for workholding. The part is an aluminum bracket with several cutouts, about 150 mm long and 50 mm wide, with tight tolerances on critical faces. The main challenge is securely clamping it without distorting the part or risking movement during machining. Currently, I’m considering adding clamping tabs or temporary holes for fixturing, but I’m not sure about the best placement to minimize post-machining cleanup while keeping everything stable. The cutouts are spread out, leaving the edges mostly linear and intact. I was thinking of adding tabs on the sides, but I’m worried they might introduce some bending when I clamp down.

Hi all, I’m machining 60 mm deep, 20 mm diameter cavities in Aluminum 6061 with ±0.05 mm tolerances. Issues like chatter, tool deflection, and poor chip evacuation make it tricky, and I’m concerned about overheating and tool wear. Do you have any advice on tool selection, speeds/feeds, cooling, or strategies to balance precision and efficiency?

Hi all, I’m new to the world of tolerance stack up and working on a snap-fit assembly with five injection-molded ABS components. In prototypes I’m encountering inconsistent engagement forces, likely due to tolerance accumulation across mating features. How can I use GD&T or tolerance analysis software to identify and control critical variations? Are there any beginner-friendly best practices or tools you’d recommend to ensure consistent performance?

Hello ,I’m using an SLA printer with high-resolution resin (25-micron layer height), for a miniature satellite component prototype, specifically a multi-chamber fluid management system intended for microgravity environments. The design features intricate internal structures, including floating baffles and valve mechanisms, which are essential for controlling fluid flow. I’m facing challenges with support structures that interfere with these delicate internal components. What strategies do you recommend for optimizing support structures for floating internal components without compromising the part’s functionality or surface finish? The final product needs to maintain tight tolerances (±0.05 mm) and smooth internal surfaces for optimal fluid dynamics.

Hi, I’m struggling with efficiently normalizing my tube cuts in SolidWorks (for a complex tubular frame design for a lightweight racing chassis). The frame consists of both round and rectangular tubes with various intersections and joint angles. My workflow involves creating sketches for each cut, which is slow and inaccurate, especially when changes are needed. I’ve tried using the Weldments feature, but I’m not satisfied with the results for complex joints. Is there a way to automate creating normal-to-surface cuts for multiple tubes simultaneously? How do you handle situations where tubes intersect at compound angles?

Hi everyone, I’m designing an automotive underbody heat shield using 0.8 mm thick aluminum alloy 5052-H32 for progressive die stamping. My main challenge is determining the optimal draw depth for complex geometries without risking material thinning or tearing. Some areas of the part require a draw depth of up to 25 mm. Given the material properties and thickness, I’m concerned about maintaining part integrity during the deep drawing process. I’m looking for advice on:Calculating the maximum safe draw depth for this specific material and thicknessStrategies to achieve deeper draws without compromising material integrityHas anyone worked with similar geometries and materials? What approaches have you found successful in optimizing draw depth while ensuring part quality?