Getting it made

[RickRST]

Hi all, first post on the forum.

I'm currently learning solidworks with a view to designing some very simple parts. Currently i'm looking at a flange and a thermostat housing. I imagine these to be made from billet aluminium.

I want to know if i'm wasting my time, if one offs or very small qty's aren't within the scope of a private individual. I have designed PCB's from scratch before using Orcad, generated gerbers and had these produced with very good results. However, I am aware that machining a block of solid alloy is a far more involved.

Thanks, Rick

 

[TheTick]

This isn't really a SolidWorks issue. Make some drawings and get some quotes.

 

[CorBlimeyLimey]

Take a flange and housing to a few local machine shops to quote on.

 

[ShaggyPE]

I have not used their services, and they require you to generate your model in their software, but it is worth a shot.

http://www.emachineshop.com/

-Dustin
Professional Engineer
Certified SolidWorks Professional
Certified COSMOSWorks Designer Specialist
Certified SolidWorks Advanced Sheet Metal Specialist

 

[FreddyB]

Hi Rick,

It's just a cost thing. Many suppliers will be willing to make a one off but the charges will be relatively high. Having said that, don't just get a couple of quotes, get about 5 or more if you can. They will vary a lot.

Do make sure that your part doesn't include features i.e.small internal rads that will put the cost up for no reason. If, as an electrical engineer, your mechanical skills are not that great, please ask the contractors if they can see any particular problems with the part you describe.

 

[RickRST]

Thanks for the replies.

Freddy,

yes as an Electrical engineer I don't know the ins and outs of manufacuring. My first thoughts were I didn't want to deisgn something that would be ridiculously expensive when it needn't be with a few simple changes. Are there people on these forums that would take a look at an assembly and make comment?

First item i'm going to look at is a thermostat housing which is more or less a cube with 3 mounting holes and 4 pipe outlets. The original is plastic and very prone to cracking. I'd like a billet alloy item - i'm thinking that a 2 piece item may be cheaper to produce that a 1 piece?

Aplogies if this is not within the scope of this room.

Rick.

 

[MadMango]

Any good machince shop should be willing to spend a few minutes with you in order to discuss design and changes to bring the cost down some amount, hinging on the hope that more work will come thier way from you.

"Art without engineering is dreaming; Engineering without art is calculating."

Have you read faq731-376 to make the best use of these Forums?

 

[dgowans]

RickRST,

You can get an online quote from First Cut Prototype for machined parts. They will work directly from your Solidworks model and, in the event that your model doesn't fit their process, will make suggestions as to what needs to change for them to be able to make the part.

One of the things that they will likely flag as a concern is minimum radius considerations. Study what they come back with and try to extend the concepts to other areas of your model. Like FreddyB said, sharp internal corners will drive cost up. Remove only the material you need to.

 

[ArtL]

See if you can find an automotive / motorcycle thermostat and housing close to what you want,need. It may be a lot cheeper to modify an existing housing, IE.. more in/out ports, bolt pattern ect. For what you want, a prototype of this sort may be really cheep. I do Hot Rods and Hot Bikes for a hobby so I know all about custom one off "stuff".

 

[drawoh]

RickRST,

Machining is a good process for one-off parts. Today, machinists use CNC machines even for one-offs.

Machining from billet is cool and economical for small parts. It can get expensive for large parts. Estimate the size and weight of your billet. Aluminium is 0.1lb/in³ or 2800kg/m³. The weight/mass goes up with the cube of your linear size.

Do not bother designing from extruded sections. Extrusions come in 20ft lengths. The shop will not order one to make your one-off 2inch part. Extrusions also tend to be warped and twisted. Fabricating from plate is okay.

JHG

 

[DiegoLGraves]

RickRST, you may also consider fabricating the housing out of sheet aluminum. It's often easier and less expensive to make one piece cut, formed and welded than to have one pc machined. Holes and threaded fasteners are also easy and cheap to add.

Just another thought. Diego