Complimentary Design Review for Fabricated Assemblies

Take advantage of a 30-minute virtual meeting with one of our sheet metal applications engineers to review your project. This is a great opportunity to address any questions or concerns you may have. Common topics for discussion include:

  • Exploring assembly construction choices
  • Managing tolerance stack-up
  • Evaluating cost optimization strategies

Our online sheet metal assembly service allows you to produce functional, ready-to-use products delivered in just a few days. Every project includes design for manufacturability (DFM) feedback and expert support. You can select from a variety of finishing options to meet your design needs.

Fabricated assemblies are commonly used for:

  • Functional prototyping
  • Product testing and validation
  • Low-volume, end-use production
  • Pilot runs

File Format and Setup

The preferred file format for assemblies is an upper-level assembly STEP file. For SOLIDWORKS users, we recommend submitting a solid assembly file (.sldasm) along with separate component files (.sldpart).

If your project involves weldments or requires welding, please include a 2D drawing with your CAD submission.

If AIXI will not be assembling your project components, a solid (or top-level) assembly file is not necessary.

Materials

Select from commonly used materials that are ideal for creating final assemblies. Industry-standard material thicknesses are applied to all material types. Typical materials used in fabricated assemblies include:

  • Aluminum 5052-H32
  • Low carbon steel CR 1008
  • Stainless steel 304/304L
  • Stainless steel 316/316L

These materials are known for their excellent formability, weldability, and outstanding corrosion resistance in challenging environments.

Other materials, such as pre-plated steels (galvanized or galvannealed), are also available. However, these pre-treated coatings make these materials more suitable for rivet-based assembly construction.

For further details on sheet metal types and thickness ranges, our material comparison tool is available.

Assembly Construction Guidelines

When designing your assembly, there are various options for customization. Keep the following considerations in mind for your next sheet metal project:

Maximum Assembly Size (when fully assembled): 47 in. x 39 in. x 36 in. (1194mm x 991mm x 914mm)

Available Assembly Methods:

  • Welding (seam, tack, and stitch welding techniques)
  • Riveting (pop and solid rivets)
  • Hardware insertion

Formed Features

  • Linear Bending: Achieved using a press brake with tooling options ranging from 0.010 in. to 1 in. (0.254mm to 25.4mm).
  • Large Radius Bending: Utilized for functional or aesthetic purposes, performed through bump forming or roll-forming techniques.
  • Punch-Formed Features: Includes louvers, ribs, and dimples to enhance strength, ventilation, or design functionality.

Machined Features

CNC post-processing enables the creation of intricate design elements that are difficult to achieve through laser cutting, punching, or press brake forming alone. These enhancements include:

  • Pockets for weight reduction or component integration.
  • Precision Holes and Cutouts, especially those prone to deformation during forming.
  • Flange Length Reduction to meet specific design and assembly requirements.

Tolerances

  • Standard sheet metal tolerances apply to assembled components. For detailed specifications, refer to our design guidelines.
  • If you have specific tolerance concerns, such as stack-up or fitment, schedule a free 30-minute design review to discuss your project requirements.

Inspection Reporting Options

We offer various inspection and certification options to ensure quality compliance:

  • Material and/or finishing certifications available upon request*
  • Inspection documentation, including First Article Inspection (FAI)*
  • All parts and assemblies undergo dimensional and visual inspection per our quality standards before shipping

*Requests must be made before placing an order. Available options are shown in your online quote.

Hardware Insertion Guidelines

We offer a wide selection of stocked fasteners from leading brands like PEM and Southco.

File Formatting:

  • Preferred Method: Include hardware in your 3D CAD model as separate solid bodies from the main sheet metal component. When possible, use industry-standard part numbers (e.g., CLS-M6-1).
  • Alternative Method: Upload your CAD file without hardware and provide a 2D drawing specifying hardware types and placement locations.

Available Hardware Options for Customization

Enhance your project with a variety of hardware options, including:

  • Self-clinching nuts
  • Self-clinching standoffs
  • Flush-head studs
  • Miniature self-clinching nuts
  • Self-clinching flush nuts
  • Flush-head pins
  • Self-clinching blind fasteners
  • Thin sheet non-flush studs
  • Self-clinching lock nuts
  • Self-clinching micro pins
  • Panel fasteners
  • Lead Time

Incorporating hardware into your part design does not impact production lead time.

Design Considerations for Hardware Inserts

  • To ensure proper grip and secure fastening, the hardware insert material must have a hardness equal to or greater than the sheet metal it is inserted into.
  • For more details on hardware compatibility and material selection, refer to our Design for Manufacturability Toolkit. Additionally, our hardware integration guide provides insights into best practices for hardware placement and application.

Welding Guidelines

Welding is an effective method for joining metal components into a final assembly. We offer MIG (Gas Metal Arc Welding) and TIG (Gas Tungsten Arc Welding) as our primary welding techniques.

Welding Design Considerations:

  • To prevent material warping or “oil canning,” welded assemblies must have a minimum material thickness of 0.042 in. (1.07mm).
  • Maximum material thickness for welded assemblies is 0.250 in. (6.35mm).
    Clearly indicate welding locations on your 2D drawing.
  • If not necessary for functionality, avoid specifying a welding method.
  • All welded components must be made of compatible materials.

For added flexibility in joining components, riveting is an alternative to welding. Rivets provide a secure mechanical connection without the heat distortion associated with welding.

Lead Time: Adding welding to your assembly increases production time by 1 business day.

Finishing Options for Assemblies

Beyond geometric and feature customization, our finishing services enhance both the appearance and durability of your components and assemblies. Available finishing options include:

  • Plating
  • Powder coating
  • Wet painting
  • Masking
  • Part marking
  • Metal surface finishing

Lead Time: Most finishing processes add 1-2 additional days per finish. For more details, refer to our finishing options page.