When it comes to complex mechanical parts, poor structural design can often lead to hidden costs—inefficient assembly and unstable machining quality. Recently, we helped one of our automation equipment clients redesign a mounting bracket by integrating sheet metal bending and CNC machining, ultimately achieving:
30% improvement in assembly efficiency
15% cost reduction
Significant improvement in dimensional consistency
Project Background
The original component was a three-piece sheet metal bracket used to mount control panels. It required manual welding and subsequent CNC machining for positioning holes and fitting features. Over time, the client encountered recurring issues:
Welding distortion caused alignment problems during CNC setup;
Assembly required 2 operators and over 20 minutes per unit;
Tolerance stack-ups led to misalignment and on-site rework.
Optimization Goals
After engaging with the client’s engineering team, we defined the following goals:
Maintain the original external dimensions and functions;
Eliminate welding, reduce part quantity;
Achieve ±0.1mm machining tolerance for key features;
Reduce labor and time without significantly increasing cost.
Technical Solution
We proposed a hybrid manufacturing solution that combined precision sheet metal forming with CNC post-machining, focusing on process integration and design for manufacturability (DFM).
✅ 1. One-Piece Sheet Metal Structure
We redesigned the bracket as a single laser-cut and bent sheet metal part, replacing the three original pieces.
Reinforcement ribs and locating tabs were added to ensure dimensional stability after bending;
The one-piece design eliminated welding, minimizing thermal deformation.
✅ 2. Reserved Machining Features for Post-Processing
Key positioning holes and fit surfaces were left as rough profiles during laser cutting;
After forming, the entire structure was mounted and CNC-machined to final tolerances, correcting any minor form deviations.
✅ 3. Weld-Free Assembly
Replaced welded joints with rivet and tab-lock designs for fast, reliable assembly;
Assembly now requires only one operator and no special tooling.
✅ 4. Process Flow Optimization
Reduced from three separate part numbers and process chains to a single unified workflow;
Removed 2 intermediate inspection points and 1 sub-assembly stage;
Simplified BOM, improved inventory and logistics handling.
Final Results & Client Feedback
| Metric | Before | After | Improvement |
|---|---|---|---|
| Assembly Time | 30 min | 8 min | ↓73% |
| Labor Requirement | 2 operators | 1 operator | ↓50% |
| Process Steps | 9 | 5 | Simplified |
| Tolerance Stability | ±0.2–0.3mm | ±0.08mm | ↑ |
| Overall Cost | — | ↓15% | Reduced |
The client was particularly satisfied with the simplified on-site assembly, better structural integrity, and reduced lead time. They have since invited us to support optimization on five additional components using similar strategies.
Our Perspective
This project reinforces our belief that manufacturing is not just about execution—it's about enabling better design. By integrating multiple processes and getting involved early in the design phase, we transform production from a cost center into a value driver.
We are continuing to invest in:
Standardizing our DFM assessment workflows;
Building quoting models for hybrid process chains;
Expanding our in-house process database for faster technical planning.